Designing Pressure Vessel Requires Expertise

Pressure vessels are vital components used in a wide range of industries, including petrochemicals, energy, pharmaceuticals, and aerospace. These vessels play a critical role in storing and transporting gases and liquids under high pressure, making them essential for numerous industrial processes. The design and engineering of pressure vessels are complex tasks that demand specialized expertise of mechanical engineers and pressure vessel designersto ensure safety, efficiency, and compliance with stringent industry standards. In this article, we delve into the key considerations involved in designing the right pressure vessel and highlight the importance of seeking expertise in this intricate field.

1. Understanding Pressure Vessels: Pressure vessels are containers designed to hold gases or liquids at pressures significantly higher than atmospheric pressure. They come in various shapes and sizes, including cylinders, spheres, and horizontal or vertical tanks. Pressure vessels are widely used for storing chemicals, processing fluids, generating steam, and conducting various chemical reactions.

2. Safety Considerations: The primary concern in pressure vessel design is safety. Failure of a pressure vessel can lead to catastrophic consequences, such as explosions or leaks of caustic materials that could result in injuries and damage to property. Therefore, strict regulations, codes, and standards have been established to ensure proper design, fabrication, inspection, and testing of pressure vessels.

3. Material Selection: Selecting the appropriate materials for pressure vessel fabrication is of paramount importance. The choice of materials depends on factors such as the nature of the fluid or gas being contained, operating conditions (pressure and temperature), and corrosion resistance requirements. Common materials used for pressure vessels include carbon steel, stainless steel, aluminum, and various alloys. Most hydrogen compressor manufacturers for example employ highly trained engineers that specialize in design and materials selection.

4. Compliance with Codes and Standards: Designing a closed loop CO2 extraction system for example demands adherence to industry-specific codes and standards, such as the ASME Boiler and Pressure Vessel Code and the European Pressure Equipment Directive (PED). These codes provide comprehensive guidelines of ASME pressure vessel manufacturer for the safe design, fabrication, and operation of pressure vessels, ensuring consistency and reliability in their performance.

5. Stress Analysis and Finite Element Analysis (FEA): Stress analysis is a critical aspect of pressure vessel design. Engineers use analytical methods and Finite Element Analysis (FEA) to evaluate the stresses and deformations that pressure vessels may experience under different operating conditions. This analysis helps ensure that the vessel can safely withstand the anticipated loads and pressures.

6. Thermal Analysis: Pressure vessels often encounter temperature fluctuations during their operation. Thermal analysis is crucial to understand how temperature changes affect the vessel's structural integrity and material properties. Proper thermal design is essential to prevent issues like thermal stress and fatigue, which can compromise the vessel's longevity.

7. Design Optimization: The optimization of pressure vessel design is a delicate balance between performance, cost-effectiveness, and safety. Experienced engineers take into account factors such as material selection, geometry, and fabrication methods to achieve an optimal design that meets performance requirements while adhering to budget constraints.

8. Design for Manufacturing: Efficient manufacturing is crucial for pressure vessel design. Engineers must ensure that the vessel's design can be fabricated using existing manufacturing techniques and tools while ensuring dimensional accuracy and consistent quality.

9. Customization for Specific Applications: Pressure vessels are often tailored to specific industrial applications. Each industry may have unique requirements, such as the need for lightweight materials in aerospace applications or enhanced corrosion resistance in chemical processing. Expertise in customizing pressure vessel design ensures that the vessel meets the precise needs of the intended application.

10. Non-Destructive Testing (NDT): Non-destructive testing (NDT) methods are employed during fabrication and periodic inspections to detect flaws or defects in pressure vessels without causing damage. NDT helps ensure the integrity and longevity of pressure vessels throughout their operational life.

11. Maintenance and Life-Cycle Management: Expertise in pressure vessel design extends beyond the initial construction phase. Engineers also consider the long-term maintenance and life-cycle management of the vessels, including inspection schedules, repair procedures, and criteria for retiring or replacing the vessel.

Designing the right pressure vessel is a multifaceted and critical process that demands specialized expertise. Safety, compliance with regulations, and optimal performance are paramount concerns, and any compromise in design can have severe consequences. Expert ASME pressure vessel manufacturers with a deep understanding of material science, stress analysis, thermal considerations, and industry standards are essential to create reliable and efficient pressure vessels. As technology and industrial demands continue to evolve, the importance of expertise in pressure vessel design remains indisputable in ensuring the safety and success of various industrial processes.

Mechanical Engineers That Design Pressure Vessels

For the safety and efficiency of various systems in industries such as chemical, pharmaceutical, and food processing, testing and utilizing robust equipment is crucial. Hydrostatic testing services and using an ASME pressure vessel manufacturer to build your equipment are two key factors that drive the efficiency of these operations, ensuring their smooth and uninterrupted flow.

Hydrostatic testing is a method used in numerous industries to verify that equipment such as pipelines, tanks, and vessels can withstand high pressure. This is a fundamental component of a safety protocol, as it helps mitigate any potential risks associated with system failures. Hydrostatic testing is especially important when the safety of the workforce and the longevity of the equipment are at stake.

These services primarily involve filling the vessel or system with a nearly incompressible liquid - usually water - and pressurizing it to a specific level. This process helps to identify any deformities or potential weak spots in the structure that might not be visible to the naked eye. A significant advantage of hydrostatic testing is its ability to test the strength and flexibility of the equipment without causing any permanent deformation or damage.

The criticality of hydrostatic testing becomes more apparent when considering its role in detecting system flaws before the commencement of operations. These tests ensure the reliability of the equipment and contribute to the longevity of the systems, thereby preventing unexpected shutdowns and costly repairs.

On the other hand, custom reactors play a pivotal role in the chemical, pharmaceutical, and bio-chemical industries, among others. These are specialized vessels designed to handle a variety of chemical reactions under controlled conditions. Custom reactors, as the name suggests, are built to meet the specific needs of the client, allowing for high versatility and adaptability to different applications.

Custom reactors can range from small benchtop systems for research and development purposes to large industrial-scale reactors for production. Their customizability makes them ideal for a variety of applications, including synthesis, distillation, hydrogenation, polymerization, and many others.

Having custom reactors tailored to specific industry needs is beneficial in a variety of ways. They enable the optimization of processes, help meet strict industry standards, and increase overall operational efficiency. Custom reactors are designed often for a specific type of chemical reaction, the volume of material to be processed, the desired pressure and temperature conditions, and other critical factors. The use of such reactors allows for precise control over the chemical process, thereby improving yield and efficiency.

To sum up, both hydrostatic testing services and custom reactors are are often provided by ASME pressure vessel manufacturers that follow the fabrication standards of the ASME. Hydrostatic testing services in PA will help ensure the safe operation of equipment by testing its strength and leak-resistance.

Choosing reliable and experienced pressure vessel manufacturers for these services and products is crucial for your equipment longevity. With an in-depth understanding of industry-specific requirements, such providers can offer solutions that best meet the needs of their clients. The ultimate goal is to ensure not only the safety and reliability of the operations but also their efficiency and profitability. In the rapidly evolving industrial landscape, these elements form the backbone of successful and sustainable operations.

Pressurized Gasses Need Special Storage Vessels

In the vast realm of industrial processes, the role of pressure vessels is pivotal. These containers, engineered to hold gases or liquids at a pressure substantially different from the ambient pressureare used in many different industries. From chemical and oil refineries to power plants and food processing factories, pressure vessels facilitate a variety of tasks, contributing significantly to the operational efficiency of these industries.

One specific type of pressure vessel is the hydrogen compressor. These specialized vessels are designed to handle and compress hydrogen gas, a task that demands careful engineering due to the high-pressure nature and reactivity of hydrogen. Hydrogen compressors made to spec are employed in various industries, including refineries, fuel cell power systems, and industrial manufacturing processes.

Pressure vessels come in an assortment of sizes and shapes, each designed to cater to specific industrial needs. Their construction primarily involves robust materials, such as carbon steel, strong nickel alloys or stainless steel, to withstand high internal pressures. However, the choice of material can change based on the operational environment, desired lifespan, and the type of substance stored or processed.

Pressure vessels are designed and manufactured by professional pressure vessels manufacturer who abides by the stringent safety standards outlined by the industry, which ensures the safety and functionality of these vessels. The pressure vessel manufacturersmust adhere to the rules set forth by professional entities like the American Society of Mechanical Engineers (ASME) to ensure each vessel can safely hold the gases or liquids for which it is designed. Not every fabricator can be an ASME pressure vessel manufacturer.

The variety of pressure vessels is expansive, with each type serving a distinct purpose. These range from storage vessels, heat exchangers, process vessels to reactor vessels used in nuclear power plants. All of these play a crucial role in processing and storing volatile substances under pressure, contributing significantly to industrial productivity.

The integrity of a pressure vessel largely depends on its maintenance. Regular inspections are necessary to detect any signs of wear, corrosion, or structural anomalies that could compromise the vessel's performance or safety. Non-destructive testing techniques such as ultrasonic testing, radiographic testing, or magnetic particle testing are commonly employed to assess the condition of pressure vessels.

Innovation and advancements in technology have also significantly impacted the pressure vessel industry. Enhanced design software, superior materials, and cutting-edge manufacturing techniques are continually raising the bar for pressure vessel safety, efficiency, and longevity.

In conclusion, pressure vessels, including specialized equipment like hydrogen compressors made to spec, are integral components of many industries. Their importance underlines the need for high-quality design, meticulous manufacturing, and diligent maintenance, as these elements together ensure the safety and performance of these indispensable industrial apparatus. A capable pressure vessels manufacturer is essential in this regard, providing the expertise and experience needed for these vital tasks.

Reclaiming Hydrogen from Industrial Applications for Fuel

The global shift towards clean energy has sparked an increased interest in hydrogen as a sustainable and efficient alternative to conventional fuels. As industries and governments embrace the potential of hydrogen, the demand for state-of-the-art hydrogen technologies has soared. Among these, hydrogen compressors and cryogenic hydrogen products are crucial components of the hydrogen ecosystem. Fluitron, a leading provider of high-pressure equipment and systems, offers innovative solutions in these areas, with their custom-made hydrogen compressors and cryogenic products setting new industry standards.

Hydrogen Compressors Made to Spec

Fluitron's diaphragm compressors stand out in the hydrogen market, as they are specifically designed to meet each client's unique requirements. By tailoring the design to the specific application, Fluitron ensures optimal performance, durability, and safety, which are all critical factors in the hydrogen sector.

One of the key advantages of Fluitron's diaphragm compressors is their oil-free and contamination-free operation. Thanks to the use of diaphragms separating the compression chamber from the hydraulic system, these compressors eliminate the risk of oil and other contaminants entering the gas stream. This is particularly important for hydrogen applications, where purity is essential for maintaining the efficiency and performance of downstream processes and equipment.

Additionally, the diaphragm design ensures a leak-tight compression process, which is vital for handling flammable and potentially hazardous gases like hydrogen. Fluitron's compressors are designed to meet the stringent safety standards required for hydrogen applications, such as fueling stations, electrolyzer systems, and high-pressure storage systems.

Cryogenic Hydrogen Products

Aside from their cutting-edge hydrogen compressors, Fluitron also offers a range of cryogenic hydrogen products. These solutions are designed to handle the storage and transportation of hydrogen in its liquid state, which requires extremely low temperatures (around -253°C or -423°F).

Fluitron's cryogenic products are built to meet the unique challenges posed by the extreme temperatures and pressures involved in cryogenic hydrogen applications. Their cryogenic solutions include storage tanks, cold boxes, vaporizers, and transfer lines, all of which are designed to handle the specific properties of cryogenic hydrogen.

One of the most impressive aspects of Fluitron's cryogenic solutions is their ability to maintain the integrity of the hydrogen throughout the storage and transfer process. By using advanced insulation and temperature control systems, these products ensure minimal heat leak and boil-off, thereby preserving the hydrogen's quality and reducing losses.

The cryogenic hydrogen products are suitable for a wide range of applications, such as refueling stations for fuel cell vehicles, large-scale hydrogen storage systems, and transportation solutions for long-distance distribution.

A Bright Future for Hydrogen

As the world moves towards sustainable energy solutions, the demand for advanced hydrogen technologies will continue to grow. Fluitron's custom hydrogen compressors and cryogenic hydrogen products are poised to play a critical role in meeting this demand, providing industry-leading solutions that facilitate the safe and efficient use of hydrogen in various sectors.

In addition to their high-quality products, Fluitron's commitment to customer satisfaction and continuous innovation sets them apart from competitors. By working closely with their clients to design and manufacture equipment tailored to their specific needs, Fluitron ensures that their hydrogen solutions not only meet but exceed expectations.

To learn more about Fluitron's hydrogen compressors and cryogenic hydrogen products, visit their website for detailed product information, case studies, and expert insights. The future of hydrogen is here, and Fluitron is ready to help industries harness its potential for a cleaner, more sustainable world.

Getting Hydrogen from Biogas is Beneficial for Our Planet

The world is at a critical juncture as we grapple with the challenge of transitioning to more sustainable energy sources. Among the most promising solutions is the production of clean, renewable fuels such as Compressed BioGas (CBG), Liquefied BioGas (LBG), hydrogen, and methanol from biogas. The production and storage of these fuels require specialized equipment, such as custom pressure vessels and high-pressure pumps, which are integral to maintaining safety, efficiency, and effectiveness in these processes. This article explores the role of custom pressure vessels in the sustainable production of clean energy and their benefits.

Custom Pressure Vessels: A Key Component in Clean Energy Production

Custom pressure vessels are specially designed containers that can safely hold gases or liquids at high pressures. They are manufactured to meet specific requirements and adhere to stringent safety standards, ensuring that they are suitable for various applications in the clean energy sector. These vessels play a crucial role in the storage and transportation of fuels like CBG, LBG, hydrogen, and methanol, as they are responsible for maintaining the integrity of these substances under high-pressure conditions.

Benefits of Custom Pressure Vessels in Clean Energy Production

Enhanced Safety

Safety is of paramount importance when dealing with high-pressure gases and liquids, as any leakage or rupture can lead to catastrophic consequences. Custom pressure vessels are engineered to the highest safety standards, including ASME and PED certifications, ensuring that the fuels are stored and transported securely.

Improved Efficiency

Custom pressure vessels like hydrogen compressorsare designed to optimize the efficiency of the clean energy production process. They can be tailored to specific applications, ensuring that the vessel's shape, size, and materials are best suited for the intended purpose. This customization results in better performance and reduced energy consumption, ultimately contributing to the overall sustainability of clean energy production.

Flexibility and Adaptability

As the clean energy sector is continually evolving, ASME pressure vessel manufacturers need to offer the flexibility and adaptability needed to accommodate new technologies and applications. Their ability to be designed and manufactured to suit specific requirements ensures that they can seamlessly integrate with innovative systems and processes.

Durability and Longevity

Custom pressure vessels are made from high-quality materials that ensure their durability and longevity. These vessels are designed to withstand the harsh conditions and high pressures associated with clean energy production, ensuring that they remain operational for extended periods. The long service life of custom pressure vessels translates into lower maintenance and replacement costs, making them a cost-effective solution in the long run.

Environmental Benefits

By facilitating the production and storage of clean energy, custom pressure vessels contribute to reducing greenhouse gas emissions and reliance on fossil fuels. The production of CBG, LBG, hydrogen, and methanol from biogas presents a sustainable energy alternative that can help mitigate the impacts of climate change.

Conclusion

Custom pressure vessels are indispensable in the production, storage, and transportation of clean energy sources such as CBG, LBG, hydrogen, and methanol. Their enhanced safety, improved efficiency, flexibility, durability, and environmental benefits make them a crucial component in the pursuit of sustainable energy solutions. As the world continues to seek alternatives to fossil fuels, the demand for custom pressure vessels will only grow, making them a vital piece of the clean energy puzzle.

Fabricating High Pressure Containers Requires Serious Skills

The design process for custom pressure vessels begins with a detailed understanding of the application requirements. This includes determining the maximum operating pressure and temperature and any special considerations, such as corrosive materials or flammable gases. The design must also consider factors such as the vessel's size, weight, shape, and location of any fittings or connections. 

Once the design is finalized, the fabrication process can begin. This typically involves cutting, bending, and welding the vessel's components together. Skilled welders are essential in this process, as any flaws or defects can compromise the integrity of the vessel. 

Ensuring Quality Control

High pressure vessel fabrication requires strict quality control measures to ensure that the final product meets all necessary safety standards. This includes testing the vessel for leaks and verifying that it can withstand the specified pressures and temperatures. The vessel may also need to undergo non-destructive testing, such as x-rays or ultrasound, to detect any flaws or defects in the welds. 

Safety Considerations for High Pressure Pumps

High pressure pumps are another critical component in many industrial applications. These high pressure syringe pumps are used to generate the high pressures required for tasks such as injecting fluids into a pressurized vessel. As with pressure vessels, safety is of the utmost importance in designing and fabricating high pressure pumps. 

One key safety consideration is using high-quality materials that can withstand the pressures and temperatures involved. The pump's components must also be designed to handle high pressure stresses, and proper assembly is essential to prevent leaks or other failures. 

Other safety considerations include using safety guards and interlocks to prevent accidental operation, as well as proper training and supervision of personnel who operate the pumps. 

The Importance of Training and Certification

Fabricating high pressure containers requires specialized skills and expertise. In addition to skilled welders and fabricators, the process also requires engineers and designers who are knowledgeable about the principles of pressure vessel design and the requirements of relevant safety standards and codes. 

It is essential that all personnel involved in the fabrication and operation of high pressure vessels and pumps receive proper training and certification. This includes training in welding, quality control, and safety procedures and certification by recognized industry organizations such as the American Society of Mechanical Engineers (ASME). To become an accredited ASME pressure vessel manufacturer, more that 50% of your welding crew need to be certified by the ASME training offered by this organization.

Fabricating high pressure containers such as custom pressure vessels and high pressure pumps requires serious skills and expertise. From design and fabrication to quality control and safety considerations, every aspect of the process must be carefully managed to ensure the reliability and safety of these critical components. By working with experienced and knowledgeable manufacturers, companies can ensure that they receive high-quality pressure vessels and pumps that meet all necessary safety standards and requirements.

What Are The Advantages Of Diaphragm Compressors?

Working with a reputable high pressure vessel manufacturer is crucial if you are in an industry that depends on gas compressors. Whether you are in the business of rare gas storage, gas recycling, electronics manufacturing, or metal processing, your operations would likely need to work with a quality pressure vessel manufacturer. 

How Diaphragm Compressors Work

Diaphragm compressors, also known as membrane compressors and belong to the category of reciprocating compressors. Instead of an inlet element, it compresses gases using a flexible diaphragm, thus its name. 

The diaphragm of the compressor allows the entry of gas during its down-stroke. When it flexes during its upstroke, the gas inside the storage or chamber is pushed out. A crankshaft mechanism and a reciprocating piston control the movements of the diaphragms. 

During the process, the oil or hydraulic fluid used by the compressor does not come in contact with the stored substance in the tank. There are also compressors that are non-lubricated or oil free. This is why industrial hydrogen compressor manufacturers can guarantee that there is not risk of contamination of the stored gas. This makes diaphragm compressors the ideal choice when recovering fluid materials such as pure hydrogen gases or other types of process gases. 

Working with a certified ASME pressure vessel manufacturer assures business owners, that the compressors will be fabricated to a higher standard. Often meaning there construction is reliable. 

Benefits Of Using Diaphragm Compressors

If you are in an industry that demands reliable high pressure vessels, here are the advantages of getting diaphragm compressors for your applications: 

1. Leak Free 

Diaphragm compressors using static seals have next to zero risk of leaks. Pressure vessel manufacturers can customize the seals depending on your specific needs. Most use O rings crafted from elastomeric materials, but metal-to-metal seals are used for more critical operations. 

For safety purposes, such systems are also equipped with automatic leak detection technology coupled with a control system that will minimize any leaks. 

1. High Compression Ratio 

Diaphragm compressors also offer tight compression of process gases. Some units achieve a working pressure of as much as 30,000 psi. There is also a reduced reason to worry about wear and tear with static sealing. 

1. No Contamination 

The latest diaphragm compressors in the market today do not rely on coolants or lubricants. This eliminates the risk of contaminating the contents of the high pressure vessel. If you need to handle the purest of gases, you can have a high level of confidence that diaphragm compressors will meet your expectations. 

1. Lower Energy Cost 

Diaphragm compressors operate efficiently with consistent tight compression of gases. Well-designed systems will be free from vibrations, knocks and have low noise levels. Diaphragms, often those with horizontal designs, require lower horsepower to operate, thus resulting in lower energy costs. 

Real-World Applications Of Diaphragm Compressors 

The following business operations can benefit from reputable diaphragm compressors:

• Metal processing

• Gas recycling

• Gas mixing and blending

• Electronic products manufacturing

• Hydrogen fuel stations

• Glass manufacturing

• Pharmaceuticals

• R&D in wind power sector

If your business requires reliable pressure vessel fabrication, only work with the most trusted manufacturers of large and small diaphragm compressors.

High Pressure Vessels Used in Gas Recovery

Pressure vessels are containers designed to work at pressure levels significantly higher than ambient pressure. One of their uses is to recover, treat, and extract gas. If you ask a high pressure vessel manufacturer, you’ll know these vessels are inherently hazardous. Getting a vessel certified by the American Society of Mechanical Engineers (ASME) is one way to avoid possible dangers.

The Potential Dangers Of High Pressure Vessels

Most pressure vessels are made of steel and stainless steel. These are ideal because of their durability and high resistance to heavy impact and extreme temperatures. They are also easy to clean and maintain.

However, accidents can still happen even when the most reputable industrial hydrogen compressor manufacturers use the best materials and employ the most advanced technologies to reduce the safety hazards that come with pressure vessels.

Some of the main risks of such vessels are explosion, rupture of their enclosures, and fluid leakage. When any of these occur, it can cause injury to the surrounding personnel and damage nearby equipment.

Tank explosion and rupture of an enclosure can happen when the internal pressure goes beyond the vessel’s threshold. Another culprit is the decrease in the vessel material’s resistance against extreme pressure level differences. Wrong material choices, subpar manufacturing processes, or poor operating conditions can cause this decline in resistance.

When there are cracks or gaps in the vessel, leakage can happen. And the process liquid that leaks can cause harm to the skin and/or eyes of an employee working around the vessel. Leakage failure can also cause suffocation, depending on the nature of the fluid.

Other damages that can bring forth danger include elastic deformation, corrosion, and a brittle fracture.

Finding The Right High Pressure Vessel Manufacturer

There are different pressure vessels. Storage vessels are meant to store gases or liquids at high pressure. On the other hand, process vessels are where different production processes occur (e.g., filtration, extraction). Heat exchangers are pressure vessels that facilitate heat transfer between liquids and/or gases without the involved media having direct contact with one another.

No matter what kind of vessel you need, it’s imperative to find an ASME pressure vessel manufacturer. These manufacturers ensure that their products pass stringent industry standards and tests, minimizing the risk of vessel-related accidents.

For manufacturers to keep potential dangers to a minimum, they must consider various design elements when designing and fabricating a high pressure vessel. These include:

Design pressure and temperature

Maximum permitted working pressure

Maximum tolerated stress

Joint effectiveness

Corrosion allowance

Apart from ensuring that your vessels come from high quality hydrogen compressor manufacturers, you must implement various safety precautions.

Know that pressure vessels demand timely and periodic maintenance. Doing this identifies any burgeoning issues and ensures that your tanks remain at their optimum performance.

Additionally, you must let concerned personnel undergo proper training. Everyone involved in operating these vessels must know how to use them — including their various thresholds and working capacities.

Lastly, you should invest in protective equipment. Equip your vessels with safety valves and install warning devices. Similarly, your employees must wear protective gear so that injuries can be minimized should an accident occur.

High Pressure Equipment That Laboratories Use

Laboratories need pressure vessels to perform certain experiments, research, and tests. These containers can hold gases, vapors, and liquids at higher or lower pressure levels than their surroundings outside the vessel. For instance, someone may use a lab scale high pressure reactor to test catalysts or for hydrogenation. 

Safety Matters

The nature of pressure vessels — i.e., working at a pressure significantly different from the ambient pressure — can make your gas or liquid more hazardous to humans. A vessel that doesn’t meet industry standards can cause serious and even fatal accidents (e.g., unwanted exposure to a hazardous material that leaks from the container). 

In the US, pressure vessels, steam sterilizers, and autoclaves that operate a pressure level of more than 15 psig or if their size exceeds 5 cubic feet are regulated by that State’s Boiler and Pressure Vessel Code. This code is designed to test if a piece of equipment can withstand various chemical reactions such as compression, cooling, and heating. 

Smaller vessels and autoclaves must also be certified by the American Society of Mechanical Engineers (ASME) and Underwriters Laboratory (UL) for any electronics components. Always use an ASME pressure vessel manufacturer when getting your equipment fabricated.

Some Equipment That Labs Use

There are different devices that have become a staple in many labs found in manufacturing and industrial settings. These include: 

Storage vessels. As their name says, these vessels hold liquids, gases, and vapors safely, albeit temporarily. 

Heat exchangers. People use heat exchangers to transfer heat between two fluids. You can commonly see this type of vessel in energy, bioprocessing, food, and pharmaceutical facilities. 

Boilers. These heat transfer devices use fuel, electrical, or nuclear power to generate heat. The heat is then used to boil a liquid; the vapor produced is utilized for different applications (e.g., power generation). 

Process vessels. These vessels facilitate various industrial processes. Process vessel is a broad term that comprises different types of vessels, including distillation columns, decanters, gravity settlers, industrial mixers, and chemical reactors. 

CO2 extraction equipment. A CO2 extraction machine is designed to facilitate an array of extraction processes — from supercritical CO2 extraction for cosmetic application to ethanol and cannabis extractions. 

Tips To Consider

Whether using a small or a lab scale high pressure reactor, you must take extra precautions to prevent mishaps. Here are some tips to consider: 

•  Ensure that your vessels and reactors comply with industry codes and standards and the fabricators have proper certifications. 

• Perform design calculations and take into account safety factors with the help of a qualified engineer. You can order custom pressure vessels and reactors to meet your lab’s or facility’s specific requirements. 

• Read and always follow what is written in the equipment manual. Never exceed the recommended pressure level. 

• Equip your space with shatter-proof glass or plastic screens and your employees with personal protective equipment to prevent injuries. 

Before operating any equipment, consider all the factors affecting its function. 

• Perform periodic inspections and check for signs of damage or stress. Don’t forget to test safety valves as well. Refer to the manual on how to carry out maintenance and inspection. 

• Use pressure-relieving devices to prolong the pressure equipment’s lifespan. Be sure that the devices vent to a safe location. 

What Are Isostatic Presses Used For?

Those working in the manufacturing process can benefit from the introduction of the isostatic press to their operation. Here, we’re going to look at what an isostatic press can be used for and the components that are vital to this piece of equipment. We will also share information about the purpose of high-pressure tanks when using an isostatic press, and how working with a high pressure equipment manufacturer for your equipment needs can benefit manufacturing & industrial plant operations.

What is isostatic pressing?

Developed and introduced to the manufacturing world in the 1950s, isostatic pressing began largely as a research tool but has since grown to become used widely in production sites across the globe. This technique is used primarily for crushing, pulverizing and fine powder production. Isostatic presses and also used in restoring the defects of metal castings and the production of blended materials such as ceramics, plastics, metal alloys, and composites.

There are different types of isostatic presses, but the process largely involves applying force uniformly and equally over an entire product batch, of any shape or size. This pressing action can help form product shapes designed to meet precise tolerances.

Types of isostatic pressing

There are two isostatic pressing types largely used in modern manufacturing and plant operations: cold isostatic pressing and hot isostatic pressing. Here, we will detail how each works:

Cold isostatic pressing

When you need to avoid the high cost that can come with pressing dies, cold isostatic pressing offers a unique advantage to the manufacturer. This process is largely used for isostatically processing a range of powders on a commercial scale, such as metals, plastics, ceramics, and composites. Powders are compacted into electrostatic molds in a dry or wet bag process with pressures from 5,000 psi to more than 100,000 psi.

Hot isostatic pressing

Unlike cold isostatic pressing, the hot pressing process makes use of elevated temperatures as well as isostatic gas pressure, provided by high-pressure tanks.  This process can increase the density of base materials while also eliminating its porosity. This type of pressing alters the mechanical properties and the workability of the affected material. This process is largely used to eliminate micro shrinkage in castings, as well as for consolidating powders and diffusion bonding (or cladding.)  Hot isostatic pressing can also be used in the sintering (powder metallurgy) process, for the fabrication of metal matrix composites, and for pressure-assisted brazing.

Implementing isostatic pressing in your manufacturing or industrial plant operations

If the benefits of isostatic pressing helps you avoid more costly casting processes and offers uniformity while increasing the tolerance of the materials that you use, then we recommend you find an isostatic press manufacturer. Fluitron is a High Pressure Equipment Company in PA that can help you fabricate an isostatic press for your specific needs. Get in touch with our team to learn more about how we can help or take a look through our site to find out about the services that our team provides.

Pressure Vessels That Demand Quality Engineering

The safety, durability and reliability of pressure vessels are critical and therefore require quality engineering. Companies that require pressure vessels demand the very best quality. So controlled production and rigorous testing are required.

Ensuring they’re built to ASME standards and using top-tier manufacturers for high pressure gas compressors, supercritical CO2 extraction equipment and custom reactor vessels.

What are pressure vessels?

Pressure vessels are closed containers. Housing liquids and gasses at a pressure that’s different to ambient pressure, they are often created using a range of materials.

They’re often used in a variety of industries where gas recovery systems and pressurized liquid storage are indicated. Whether that’s oil and gas, chemical or food processing industries. Types of pressure vessels that are typically created include heat exchangers, flash drums and reactors.

In order for pressure vessels to be appropriate for use, every manufacturing aspect needs to meet several standards and regulations. The ASME Boiler and Pressure Vessel Code is the one that is universally known by manufacturers of these containers.

How they’re made and their usage

Many of the pressure vessels are made of steel. Other materials include aluminum, stainless steel, and titanium, all of which are known for their durability. To manufacture such products, the steel is manufactured to the right thickness and cut to the shape required.

From a lab-scale high-pressure reactor that allows for reactions to pressure while resisting corrosive acids to a closed-loop CO2 extractor to extract cannabinoids. Both are examples of pressure vessels.

Types of pressure vessels and their material selection

There are a number of pressure vessel types that vary depending on their intended usage. A few examples include:

• Storage vessels - Temporarily hold liquids, gases and vapors.

• Heat exchangers - Help to transfer heat between two or more fluids.

• Boilers - Utilizing fuel, nuclear or electrical power as heat.

• Process vessels - Broader use for mixing and agitation, distillation, and mass separation to name but a few.

• Distillation columns - Separates a mixture of liquids based on their volatilities.

• Industrial mixers - Powered with motor-powered blades to emulsify a single mixture or multiple mixtures.

• Jacketed reactors - Maintain the temperature during a chemical reaction.

How their materials are selected

Part of manufacturing quality pressure vessels comes with knowing what materials are best for each task. Meeting the strength requirements and corrosion resistance are some of the physical attributes that can determine what materials are used. Other factors may be the return on investment and the availability of the materials in question.

The importance of quality and expert engineering

Using hydrogen compressor manufacturers that are skilled in the creation of pressure vessels and maintain ASME certifications is critical. A high quality pressure vessel requires strenuous testing at extreme conditions before being placed into service. The accidental release or leakage of contents of an untested unit can be a threat to the environment and the individuals working in close proximity of that vessel.

Producing cryogenic pumps for hydrogen gas recovery space, as well as CO2 extraction equipment for extracting botanical oils are just two applications of high pressure vessels. Visit Fluitron.com to explore other applications.

ASME Standards Dictate Fabrication of Reactor Vessels

A common piece of equipment in many manufacturing plants and facilities in various industries, the pressure vessel is designed to contain liquids, gases, and vapors at a substantially high or (low) pressure level. Often part of a relatively simple lab-scale setting, high pressure reactors should be designed and constructed in a manner that adheres to industry standards. This is to ensure workplace safety due to the nature of the reactions that may occur in pilot reactors. 

The ASME Standards

Standards are essential in relaying design requirements and relevant know-how and technology utilization in any industry. 

When it comes to standardizing vessel manufacturing, the American Society of Mechanical Engineers (ASME) is the leading organization for pressure vessel standards. Founded in 1880, ASME is recognized in around 140 countries: If a company is an ASME pressure vessel manufacturer, then it means that they have met the stringent requirements stipulated by the ASME. 

The ASME Boiler and Pressure Vessel Code (BPVC) is a globally acknowledged set of manufacturing standards that painstakingly details how boilers and pressure vessels should be made — from design and manufacturing to installation and maintenance. For instance, it dictates which materials should be used for lab scale high pressure reactors, and the careful precision in welding required for high quality pressure vessels. 

The BPVC and the several other standards the ASME details are crafted by subject matter experts. One thing that sets the ASME apart is that they accept technically qualified stakeholders regardless of their citizenship or affiliation. 

Prioritizing true consensus, their committees work independently from any political or commercial interests. The goal is to be instrumental in preserving fairness not just in trade and competition by also in innovation. 

The ASME also acknowledges that technologies, the market, and other factors affecting pressure vessel manufacturing and application can change, they see that their code is continually revised to accommodate newer techniques. 

Why Choose An ASME Pressure Vessel Manufacturer

If you need vessels for your hydrogen compressor systems or supercritical CO2 extraction equipment, choosing a manufacturer with ASME certification is important. This badge is considered a hallmark of a reputable fabricator. After all, ASME is known to carry out strict inspection procedures before it provides any certification to an applicant. 

One of the most impactful benefits of teaming up with an ASME-certified manufacturer is the guarantee of the quality of the final output that you’ll receive. If your pressure vessels and boilers meet quality standards, then you can ensure that they will perform superior to those that were manufactured without these standards. 

A corollary to quality is safety. Pressure vessels are inherently hazardous because of their nature: They’re meant to store substances at a pressure level different from ambient pressure. Over time, if they’re not maintained or constructed correctly in the first place, cracks and damage can appear. This will lead to leakage, which, in turn, can cause fires, poisonings, suffocations, and explosions. If their capacity is not properly calculated or followed, it can also cause them to shift weights and in close proximity. 

By preventing accidents involving vessels and boilers, then you can protect your people and the immediate environment that they’re in. This boosts productivity, reduces costs (including insurance expenses), and improves your reputation — all things you need to get ahead of the competition. 

Four Types of Compressors Used in Gas Recovery Systems

There are many applications of compressed gas being used in the world around us. In many cases, gas is a byproduct of a process that manufacturers try to capture these gases before they are released into our environment. Hydrogen gas recovery systems are often a part of an overall extraction and refining process, and these systems are designed to capture gas and vapor compounds that can be used or resold to gas purification partners.

These are the four main types of compressors used in processes involving oil and gas production.

Diaphragm

Reciprocating gas compressors are also referred to as a positive displacement compressor. In this system, the movement of a piston (driven by a crankshaft) drives the compression of the gas. One of the three kinds of reciprocating gas compressors is the diaphragm gas compressor (the other two being the single-acting and double-acting compressors).

A specialized iteration of the reciprocating compressor, a diaphragm compressor uses a motor-mounted concentric that provides movement to a flexible disc. The role of the disc is to expand and contract the compression chamber’s volume alternatively — mimicking how a diaphragm pump works.

When the chamber’s volume is reduced, it pushes the gas out of the compressor. In this compressor, the lubricating oil from the compressor or the hydraulic fluid doesn’t come in contact with the process gas. This maintains the purity of the compressed gas, making it the go-to compressor type for industries that require very clean air (e.g., medical players).

Rotary

Gas compression players typically categorize compressors into positive displacement and dynamic. Each of these two further comprises two sub-categories. For positive displacement, you have the rotary and reciprocating compressors.

Rotary compression systems, as their name states, compress gas using a rotary motion. A rotor rotates the shaft, which then drives the compression process through the eccentric motion of an impeller affixed to the shaft. The shaft rotates around its axis.

During the process, a vacuum is created at the center of the impeller blades, creating a suction area through which the gas enters the impeller. As the impeller spins, the gas is compressed to a higher pressure, and when the gas reaches the end of the impeller, it exits and travels back towards the center part. At this point, the gas passes through the gap between the impeller and the housing. Once again, the gas is compressed, and its pressure increases. Finally, the gas leaves the impeller and goes into the outlet pipe.

Rotary compressors have different types including lobe, screw, liquid ring, scroll, and vane.

Centrifugal

The gas is moved from low to high pressure inside a high quality pressure vessel. In dynamic compressors, a velocity head is being imparted to the gas, which is then transformed into a pressure head as the gas enters the discharge line.

Gas and nitrogen compressor manufacturers further classify dynamic compressors into two: centrifugal and axial. In the former, velocity is imparted to gases through high-speed impellers. The spinning impeller moves the gas outward and then the gas expands in a casing volute. In the casing volute, the pressure of the gas rises as the velocity slows down.

Axial

Axial compressor — one kind high pressure compressor is used in some hydrogen compressor systems — delivers large flow volumes at greater pressure ratios, thanks to the unidirectional flow of the air that it facilitates. This compressor is usually used by industries that require a high flow rate with efficiency. They can be found in many gas turbine plants and natural gas pumping stations.

The Colors of Hydrogen Recovery

Being the most abundant substance in the entire universe, it comes as no surprise why hydrogen vital to so many different applications. But for hydrogen atoms to be usable, they need to be split first from other atoms (they’re often attached to another atom, like oxygen and carbon dioxide).

With the help of hydrogen compressor systems, hydrogen atoms can be extracted, compressed, and stored for future use. Today, compressed hydrogen is being utilized to provide cleaner energy, produce fertilizers, and process food to name just a few of those applications.

Hydrogen, in itself, is an invisible, colorless gas. But in the energy industry, there are color codes used to identify how that hydrogen was sourced and produced. Here are the different colors of hydrogen recovery.

Brown/black hydrogen. Long before any manufacturer of electrochemical hydrogen compressors existed, people generated hydrogen by transforming coal into gas. This old method is the most environmentally damaging — which is why the colors brown and black hydrogen is used to describe hydrogen recovery from fossil fuels. Brown hydrogen refers to hydrogen produced using lignite coal; black for bituminous coal.

Blue hydrogen. To have cleaner hydrogen, people began recovering hydrogen from natural gas by mixing natural gas with hot steam and a catalyst. The result is hydrogen and carbon dioxide splitting. The hydrogen is then stored and the CO2 is also captured to minimize the effects on our environmental. The CO2 is repurposed in other applications.

Gray hydrogen. Similar to blue hydrogen, gray hydrogen is generated through natural gas reforming. The only difference is that the CO2 byproduct isn’t captured after the process.

Green hydrogen. Considered the ideal color of hydrogen, the green hydrogen is produced through electrolysis. This process, often used with a hydrogen compressor systems only has hydrogen and oxygen as its by-product. By not using (and producing) polluting chemicals and utilizing renewable energy sources to perform the electrolysis, green is the cleanest color of hydrogen. Its why key players involved in green hydrogen recovery are aiming to increase their output. By 2030, it’s estimated that green hydrogen generation will increase 22 times than today’s output.

Turquoise hydrogen. Though its still relatively new, turquoise hydrogen is already attracting attention and is hugely considered to be a better commercial option in the near future. Turquoise hydrogen is produced through methane pyrolysis. It’s a fundamentally new process, technologically advanced, requiring relatively smaller amounts of energy to split hydrogen atoms from solid carbon. Similar to blue hydrogen, its cleanliness depends on how the solid carbon can be captured so that there will be little to no greenhouse gas emissions.

Pink hydrogen. Today, many hydrogen compressor manufacturers are focused on producing cleaner energy — more green hydrogen, to be more exact. But there are other cleaner colors of energy as well. Pink hydrogen, for instance, is much like its green counterpart, only that it uses nuclear energy to fuel that electrolysis process.

Yellow hydrogen. If pink hydrogen’s electrolysis process uses nuclear energy, yellow hydrogen uses solar power. In generating green hydrogen, a manufacturer may use a combination of various renewable energies, such as solar and wind.

Hydrogen can be the fuel of the future that will help shape economies and how people live. With advancements in technologies that can help scale clean hydrogen, it can be used in vital sectors such as power generation and transport.

How Hydrogen Gas is Powering Our World

The shift to using more renewable energy sources is brought forth by the world’s collective effort to minimize greenhouse gas emissions from fossil fuels. But while they’re cleaner and safer to nature and us, the power that they produce can be intermittent. To address this challenge, industry experts are turning to sustainable energy storage in the form of hydrogen fuel cells, the production of which entails the use of hydrogen compressor systems and safe storage solutions. 

The Demand For Renewable Energy

Fossil fuels are the traditional source of energy for most parts of the globe. They provide stable power and are easier to supply. However, they’re finite and produce harmful emissions. Hence, the rise of the demand for alternative sources. 

Wind, solar, bioenergy, and hydropower are popular renewable energy sources. According to the International Energy Agency, these renewables are expected to account for about 18% of primary energy in 12 years. 

Manufacturers of high-pressure gas compressors are one of the industry players involved with ways to compress, store and transport hydrogen gas more cost-effectively because of the demand for their hydrogen gas compressors. One of the biggest challenges of using hydrogen fuel cells as an energy source is their market stability. For instance, energy harnessed from winds won’t be the same throughout the year because wind conditions vary on a daily basis. The same is true for solar energy. 

Therefore, these renewables must be properly stored once produced. And as stated, one of the most viable ways that experts are looking into is the use of hydrogen. 

Hydrogen As A Flexible Energy Carrier

Hydrogen is a gas with many applications. It’s used to treat metals, produce fertilizers, and process the very food that people consume. Back in the 50s, the folks at the National Aeronautics and Space Administration (NASA) have even used it (in the form of hydrogen fuel cells) to run their spacecraft’s electrical systems. 

Hydrogen is considered a flexible energy carrier — it can be compressed and stored in solid or liquid form. It can be produced from various sources (e.g., Natural gas, a byproduct of petroleum refining), it’s a potent option as a top long-term energy storage solution. But harnessing hydrogen has also been more common with the increased use of syngas in the fuel cell technology market.

The problem, however, is that its production from sources that have a low carbon footprint can be too expensive. To address this, experts are turning to electrolyzers, which break water down into oxygen and hydrogen with the use of (renewable) electricity. The hydrogen produced, in turn, is stored in tanks until power is demanded. When the need arises, the hydrogen will power fuel cells to produce zero-emission energy. 

The use of hydrogen in conjunction with hydrogen fuel cells provides a longer-term energy storage solution (batteries can also be used as non-fuel-based energy storage but it’s only viable for a short period). 

Electrolyzers, together with high-pressure gas compressors, are also advantageous because the hydrogen they produce is pure. Additionally, they can be produced directly at a certain location where there’s energy demand. 

We can all look forward to a future powered by an element as abundant as hydrogen with such technologies. Fluitron is a high pressure equipment company in PA that is one of those hydrogen compressor manufacturers that continues to exceed the needs of energy engineers with their ability to deliver high quality gas recovery systems that are needed by manufacturers.

Testing Laboratories Use Special Small Scale Vessels and Tanks

Chemical and pharmaceutical products are helpful in people’s daily lives. But before they hit the shelves or are used as an ingredient for another product, there’s a detailed process that transpires in a manufacturing facility. From custom reactor vessels to stainless steel tanks, a chemical manufacturing plant that produces such products uses a complex variety of machines to facilitate quality assurance. 

Before fully producing a chemical or a pharmaceutical product, manufacturers also conduct small-scale production tests first. They rely on high pressure vessels and tanks to assess a product’s quality and safety by performing necessary modifications accordingly. 

Reaction Chambers

Custom reactor vessels are secure chambers in which a chemical reaction occurs. Chemical reactions such as oxidation-reduction (or the transfer of electrons between two species) and hydrolysis (which involves the reaction of a water-containing organic chemical to produce new substances) are critical parts of many product development processes — especially in the field of pharmaceuticals and food and beverages, among others. 

Process tank manufacturers for labs and QA departments employ modern and sophisticated custom pressure vessels to aid industry manufacturers in testing products without contaminating the particles or substances. 

A reaction chamber is generally composed of the following:

An injector head

A catalyst bed

An upstream plenum mixing portion

A downstream exhaust plenum

An upstream and downstream temperature and over-temperature control

Before they’re made available in the market, these reaction chambers themselves are also tested first to evaluate if they can withstand different catalyst configurations. The chambers, which are essentially a network of heat exchangers, contain catalysts or substances needed to ensure that a certain chemical reaction occurs. 

Stainless Steel Tanks

Process tank manufacturers recognize that there are many applications of stainless steel tanks — from storing ingredients to mixing of substances. They design and build these tanks to be durable so that they to handle the many tasks that it will perform. 

They are also available in various sizes, depending on their function.

For instance, the standard size of a storage tank ranges from 1,000 to 50,000 gallons; 100 to 10,000 gallons for mixing tanks; 100 to 500 gallons for clean-in place tanks (these tanks are used to clean interior surfaces of process pipes and vessels); 100 to 300 gallons for clean-out-of-place tanks (tanks that are in charge of cleaning process items like valves and hoses that CIP tanks can’t clean). 

This range of tanks are part of a system that handles small-scale production tests in a manufacturing plant. Apart from the size, they also come with various designs to cater to the different needs of different manufacturers. As an isostatic press manufacturer, we can also help with pulverizing equipment and pilot plant reactors.

These tanks can be single-shelled, insulated or jacketed tank. They can have a cone-shaped or a flat-pitched bottom designs. If these will be used in conjunction with other product testing components, they can also have a heat transfer jacket on one side and a vessel at the bottom. Their top and side entries can also be configured to match a manufacturing plant’s requirements. 

This level of customizability allows process tank manufacturers in PA create a system that best suits their needs. Ultimately, it helps in facilitating small-scale testing, which are crucial to the quality, potency, and safety of a final product.

The CO2 Extraction Process: What You Need To Know

When you think of carbon dioxide, you probably define it as the gas that we, humans, exhale. Environmentalists know it as a primary greenhouse gas that is harmful to the atmosphere. But did you know that CO2 is widely used in many different industries such as food and beverage, cosmetics, and pharmaceuticals? With the aid of a supercritical CO2 extraction machine, CO2 gas is used to extract natural oils and nutrient rich substances from a naturally occurring bioproduct. 

What Is Supercritical CO2

When CO2 is heated and pressurized above 1071 psi and 31.1°C, it reaches its so-called supercritical state. In this state, elements will both have liquid and gas properties. Supercritical elements are versatile tools for processing various extracted products. 

What makes supercritical CO2 advantageous in many applications is that it has high density and low viscosity. They can easily effuse with solids and reach small spaces and pores like gas and act as a liquid solvent to dissolve materials well. On top of this, most extractions leave no residual solvents, are non-toxic, and are more economical than other supercritical gases to maintain. 

A cleverly designed and engineered supercritical CO2 extraction machine will also help you manipulate bioproduct extractions, allowing these elements to bond with other components within your recipe. 

The CO2 Extraction Process

A powerful solvent, CO2 can extract compounds from a raw material (like plant and food) without damaging the compounds’ characteristics and essence. 

More often than not, a pressure vessel manufacturer would need to fabricate the machine since gases under pressure will be part of the extraction process. 

The CO2 extraction process entails the following: 

• Feeding of CO2 into the extraction machine

• Heating and pressurization of CO2 to reach its supercritical state

• Penetration of the supercritical CO2 into the surface of a raw material

• Extraction of desired substances from the raw material

• Heating of the supercritical CO2, turning back into a gas

• Evaporation of the CO2

• Obtaining the extracted substance from the raw reservoir designed to capture material

As stated, CO2 leaves no residual solvent and is non-toxic. So, you can guarantee that the extracted substance is clean and safe. Because CO2 gas is also inert, the extract's properties won't be altered. 

Uses and Applications

Players in various industries can tap a reputable pressure vessel manufacturer to source supercritical CO2 extraction machines and use them for various applications. 

Today, CO2 extraction is commonly used to extract pure cannabidiol or CBD from the cannabis plant, essential oils for the fragrance industry and ethanol for the energy industry. The growing hemp industry uses this process to harness the true and natural potency of CBD to treat a wide array of conditions such as anxiety, depression, insomnia, Alzheimer's, Parkinson’s, and other cancer-related pains and symptoms. 

It also has pharmaceutical and cosmetic applications. CO2 extractions can be used to extract vegetable oils from raw plants and use them as essential ingredients in many medicinal and aesthetic products. 

This extraction technique is also used in beer brewing. Because of the easy manipulation of CO2, beer manufacturers can perform selective extraction of alpha and beta acids, which can then influence a beer’s flavor and aroma. A closed loop CO2 extractor is also employed to extract caffeine from coffee beans and produce the popular decaffeinated coffee. 

Besides the food and medicine industries, experts also use supercritical CO2 and the CO2 extraction process for research and academic purposes.

Compressing Hydrogen Gas for Fuel Cell Manufacturing

In the US, greenhouse gas emissions have increased by 6% from 2020 - 2021. In an effort to help reduce the dangerous levels of harmful gases like carbon dioxide into the atmosphere, several industries are using more environmentally friendly alternatives like solar, wind and hydrogen fuel cells. Typical hydrogen fuel cells are completely carbon free with the only byproducts being electricity, heat and water.

The use of hydrogen fuel cells is not only known for reducing carbon emissions. They also help reduce the demand for foreign oil, are more flexible in terms of installation, help reduce operational expenses, and are recognized as highly reliable. 

How A Hydrogen Fuel Cell Operates

For hydrogen fuel cells to have peak performance, the purest form of hydrogen gas is required to feed the fuel cell device. A network of anodes and cathodes are designed to strip hydrogen electrons via an electrochemical reaction within the device. Therefore, we need a sustainable source of hydrogen fuel and a way to capture and store that fuel. 

Natural gas is the main methane source for hydrogen gas production and landfill Bio-gas runs a close second source. Industrial producers and landfill operations are now being equipped with hydrogen compressor systems to capture hydrogen gas and other byproducts during combustion process. This effort to reduce carbon emissions and recover valuable gases is a winning combination for our environment. The hydrogen gases are then purified and reused in the production of fuel cells.

To understand this better, you need to have an idea of how these fuel cells operate. 

These hydrogen compressor systems are often made by ASME pressure vessel fabrication experts that follow well engineered designs for high pressure compressors. A typical hydrogen fuel cell has two electrodes (anode and cathode), an electrolyte, a fuel source (in this case, hydrogen), and a power supply. Hydrogen fuel passes through the anodes creating positively charged protons and negatively charged electrons. The electrons then convert to electricity through this chemical reaction.

The hydrogen molecules in the anode side are broken down into protons and electrons with the use of a catalyst. In most fuel cells, platinum is used as the catalyst. While the protons go to the cathode side through the electrolyte, the negatively charged electrons pass through an external circuit. It is in this section where the electrons generate electricity. 

After the electricity is produces, the electrons then combine and mix with oxygen to generate water and heat. 

As previously stated, the performance of hydrogen fuel cells will be better if there’s a higher purity level of hydrogen. This can be accomplished by contracting with a manufacturer of electrochemical hydrogen compressors that understands the process and is skilled at fabricating pressure vessels that operate at extremely high pressures. 

These advanced gas recovery systems are designed to prevent leakage or contamination. This preserves the quality of the hydrogen gas being used to produce the fuel cell. They’re an essential component of the whole fuel system that plays a vital role in the clean and efficient production of electricity. 

Why Choose Hydrogen Fuel Cells

When you think of hydrogen fuel cells, you may typically associate it with electric vehicles, which are a great alternative to the petroleum reliant cars that emit harmful emissions. However, there are many other fuel cell applications apart from transportation. Fuel cells can also be used for material handling and emergency backup power systems. It can also be used to fuel jets and power homes. 

There are several advantages to using hydrogen fuel cells. First off, hydrogen is an abundant resource. Because it’s non-toxic, it also won’t produce dangerous carbon emissions When industries are equipped with high quality hydrogen compressor systems, we can capture many of the harmful hydrocarbons being expelled into our environment. 

Fluitron is an ASME pressure vessel manufacturer with the skills and experience required for Bio-Gas compressor manufacturing.

How Pressure & Temperature Are Used To Alter Metals

Sometimes, traditional forming and melting methods can’t produce the exact parts or materials needed for a particular piece of equipment or structure. This is where powder metallurgy comes in. Isostatic pressing is a process that uses isostatic pressing equipment to apply a mixture of pressure and temperature to pulverize materials into powders. From these powders, super alloys can be made. We also see applications in the additive manufacturing sectors today.

How Isostatic Pressing Works

Using specially designed vessels made by an isostatic press manufacturer, a gas or liquid is utilized to apply pressure on powders placed in elastomeric molds. This compaction happens in hydrostatic conditions — meaning, the pressure, which ranges from 5,000 psi to above 100,000 psi, is applied uniformly throughout the metal powders contained in the mold. 

This process is also called cold isostatic pressing (CIP). It can be used to press a variety of powders — including metals, ceramics, and even plastics. 

CIP can be done either in a wet bag or a dry bag pressing operation. The former entails the use of independent molds. The molds containing the powder materials are submerged in the pressure vessel and removed once the pressing is done. The pressurized and compacted material will then be retrieved from the molds as a unified component. Often other processes are applied to harden or solidify the part being made.

In the dry bag process, the mold is already incorporated into the vessel itself. Instead of retrieving the part after pressing, a special mechanism will be responsible for ejecting the compacted powder from the pressing mold. This method is more efficient when the press is purposely built. 

When the isostatic pressing is performed at a high temperature (typically 2000°C), it is called hot isostatic pressing (HIP). The elevated temperature helps in removing porosity in the part being produced. As porosity decreases, density is effectively increased. This results in a part that has impeccable mechanical properties — one that can retain its shape long after initial pressure was applied. 

Because of these characteristics, HIP is used in various fields. Its application includes pressure sintering of powder often used to create parts for engine turbines and aircraft. Diffusion bonding (used in nuclear fuel assemblies) eliminates casting defects and micro shrinkage and repairs parts damaged by creep or fatigue. 

The Advantage of Isostatic Pressing

Unlike traditional uniaxial presses, isostatic pressing can produce parts that have high densities and typically complicated shapes. With the help of the right isostatic press manufacturer, engineers in various industries can design specific elastomeric molds to achieve the shape that they desire for a specific part. 

Hot isostatic pressing also guarantees the consistency of mechanical properties of the parts being manufactured. HIP improves a part’s impact and tensile strength as well as its ductility. 

Customers with a large or a complex compacting project can benefit from the cost-effectiveness that isostatic pressing provides. 

The Right Isostatic Press Manufacturer

Fluitron is a premier manufacturer of high quality pressure vessels, including isostatic presses, custom reactor vessels and high pressure gas compressors. Their selection of isostatic presses ranges from simple manual pressing machines to fully automated versions used by toll processors. 

Testing for Leaks in Pressure Vessels

If you need to contain gases or liquids at a pressure level higher than the ambient one, you need a high pressure vessel. These vessels are used in various industries, including petroleum refining, chemical processing, and boiler and storage tank manufacturing. 

One of the challenges encountered by facilities that use these vessels is material leakage. If there’s leakage, the pressure will decay, the gases will get contaminated, and the whole vessel will be at risk of becoming damaged. Leakes can also cause increased operational costs, decreased system efficiency, and heightened toxic emissions. 

To counter this issue, leak testing is done. And there are various ways in which a pressure vessel manufacturer can perform leak testing and ensure that their products are fit for service. Here are the seven most commonly used methods: 

Helium Leak Testing. In helium leak testing, this inert gas is used to pressurize the vessel. Then, a special device will be placed inside the vessel to trace and measure the size of leakage. Because this testing is more sensitive than most other methods, it can detect even if the size of the leakage is small. Only qualified helium leak testing services should be considered for this task.

Pressure Decay Testing. One of the most used leak tests, this method is done by using a pressure decay tester to pressurize the vessel with a non toxic gas (typically air). The gas inside the vessel is then tracked to check the amount of decay or pressure loss. From the elapsed time and the amount of decay, the leak rate can be calculated. 

Vacuum Decay Testing. In this test, a certain level of vacuum is achieved by removing all media within the vessel. Once the desired vacuum degree is attained, any increase in pressure will be monitored and recorded. Again, the amount of pressure increase, and the elapsed time will be used to determine the leak rate. 

Hydrostatic Testing. Like pressure decay testing, this technique subjects a high-pressure vessel into pressurization. However, instead of air, incompressible water will be used to pressurize the unit and subsequently determine the leak location and flow rate. Water is commonly used because it won’t impact the future functionality of the vessel. Companies that specialize in pressure vessel fabrication would most likely conduct hydrostatic testing on vessels they make for clients

Ultrasonic Testing. When there’s a pressure leak, the sound waves within the vessel are affected. Using this principle, this test involves sending ultrasound waves to the vessel. If these introduced waves are disrupted, it means that there’s a leak in the vessel. Professional personnel will estimate the leak’s location and its size. 

Radioisotope Testing. The media inside the vessel is combined with a radioisotope (e.g. Sodium-24, krypton-85). A special device is used to check if any of the radioisotope escapes the vessel. If any of the radioisotope being used has seeped out, it means that there’s a leak in the vessel. Though pricier than other tests, this type of test yields more accurate results. 

Dye Penetrant Testing. This test involves applying a white substance called a developer on one side of the vessel. A fluorescent dye is also applied on the opposite side. A vessel with a leak will enable the dye to penetrate and the wall, appearing on the side where a developer was applied.