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Exothermic Generators

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Exothermic generators are inert gas generators. They are combustion type generators which create the desired protective inert atmosphere based on the controlled air-gas ratio. These generators are designed is such a way that they produce cover gases for a several applications. The exothermic generators produce cover gases from the combustion of hydrocarbon fuels. Although propane and natural gas are the most commonly used, almost any type of combustible fuel, like MAP gas or even liquid fuels, like fuel oil or kerosine can be used.

The exothermic generators are a very securely constructed and controlled combustion chamber into which a accurately measured and controlled combination of air and fuel are introduced and ignited. The mixture burns at temperatures from 2,000F to 2,800F.

Types of Exothermic Generators

There are basically two types of exothermic generators:

Lean exo gas generator: This generator produces lean exo-gas comprised mainly of nitrogen and carbon dioxide (with very little hydrogen).
Rich exo gas generator: This type of generator produces a rich exo-gas comprising little nitrogen and carbon dioxide and more hydrogen component.

The lean and the rich generator are very much similar in construction and operation. The difference between the two is the requirement of a catalyst bed in the rich exo-gas generator to make sure that there is complete cracking of the products of combustion. Both the gases are produced by changing air/fuel ratio. While the first generator is suitable for non-ferrous metals heat treatment, the second one is used for heat treatment of steel/brazing/annealing applications. In general, natural gas is the most common feed gas used in both the generators.

Composition of exo and lean gas

Gas Composition	Lean Exo	Rich Exo
CO2	11 to 13%	5 to 6%
CO	0.5 to 1.5%	11 to 12%
H2	0.5 to 2%	12 to 13%
N2	Balance	Balance

The process

The air/fuel mixture in an exothermic generator can be adjusted. This is done within limits on each type of generator from leaner (which means more air) to richer (which means more fuel). Under controlled conditions, the generator burns fuel gas and air to produce an exothermic gas consisting of hydrogen, carbon monoxide, carbon dioxide, water and nitrogen. When the combustion process is completed, the gas, now depleted of any oxygen, is cooled and sent to its intended use. Sometimes the gas is dried to a very low dew point. At times it is compressed. But most of the time the gas is used as it is produced without further finishing. The gas thus produced produce a protective atmosphere used for many processes including annealing, brazing, and normalizing. In applications where a lower dew point is required, refrigerant or desiccant dryers can be utilized.

Applications of Exothermic Generators

The gas that is produced from exothermic generators are used in many applications like as follows:

Used as a non-oxidizing atmosphere in the heat treating of metals like aluminum and copper.
Provides a carburizing atmosphere for some metals.
Provides an inert and explosion-proof environment to mix chemicals, prevent combustion or formulate flammable recipes.
Annealing copper and/or aluminum.
Used in copper brazing.

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