Trace Moisture Endangering Process Safety: Residual moisture in nitrogen (≥10ppm) causes wafer oxidation in semiconductor manufacturing, with a single loss reaching 5 million RMB; in the chemical industry, it triggers catalyst poisoning, and the replacement cost exceeds 2 million RMB per time.
Limitations of Traditional Dehydration Technologies: Freeze drying can only achieve a dew point of +3℃; adsorptive desiccants suffer severe pulverization under high pressure (≥5MPa), shortening their service life from 5 years to 6 months.
Severe Energy Waste: The energy consumption for regeneration of conventional PSA drying ranges from 0.2 to 0.3 kWh/Nm³, and the annual electricity consumption of a 10,000-scale air separation system exceeds 8 million RMB.
Poor Adaptability to Complex Working Conditions: Nitrogen pressure fluctuations (0.5-10MPa), oil content (0.1-5ppm), and acidic gases (CO₂/H₂S) lead to equipment corrosion and adsorbent poisoning.
SYSTEM OVERVIEW
Yipu Nitrogen Dehydration System adopts the technology chain of “cryogenic pre-dehydration – high-pressure adsorption – heatless regeneration” to achieve:
Process Safety: Completely eliminates the risks of catalyst poisoning and product oxidation caused by moisture.
Energy Consumption Revolution: The comprehensive energy consumption is 70% lower than the industry standard, reducing carbon emissions by 2,000 tons annually (for 10,000-scale air separation systems).
Intelligent Protection: AI dynamically optimizes the adsorption/regeneration sequence, with an availability rate of ≥99.9%.
Technology Evolution
Launched a helium-compatible version in 2024, suitable for rare gas recovery in the semiconductor industry.
This solution is a core equipment for high-end manufacturing and energy industries to achieve independent and controllable ultra-pure gas.
Solution Approach
Yipu Nitrogen Dehydration and Drying Solution
Module
Technical Highlights
Performance Parameters
Cryogenic Unit
R404A/R23 cascade refrigeration, explosion-proof Ex dⅡCT4
Pre-cooling dew point -20℃, energy consumption ≤ 0.07 kWh/Nm³
Chemical high-pressure nitrogen sealing systems (5-10MPa)
Protective gas for lithium battery pole piece drying
Aerospace fuel pipeline purging
Technical Principles
Yipu Three-Stage Deep Dehydration Process
High-Efficiency Pre-Cooling (Stage 1): The -40℃ cryogenic heat exchanger cools nitrogen from 40℃ to -20℃, removing 80% of free water (dew point -20℃), with a refrigerant COP ≥ 4.0.
Lower layer: 3A-N2 molecular sieve achieves a dew point of -70℃ under 10MPa high pressure
Intelligent Regeneration (Stage 3): Adopts nitrogen self-circulation regeneration (heatless regeneration technology), saving 90% more energy than traditional electric heating.
Precision Control: Laser dew point meter (accuracy ±0.5℃) + AI algorithm dynamically adjusts the adsorption cycle.
CORE ADVANTAGE
Advantage Category
Description
Customized on Demand
Meets special working conditions; provides professional non-standard customization
Maintains low failure rate after 10,000 hours of operation; nearly maintenance-free durability
TECHNICAL STRENGTH
Leading Adsorption Dehydration Technology
Uses high-performance molecular sieve adsorbents with high water absorption capacity and resistance to acidic gas (H₂S/CO₂) corrosion, ensuring deep dehydration with a dew point ≤ -70℃.
Features an original hot nitrogen regeneration process, reducing energy consumption by 30% compared to traditional electric heating regeneration, and integrates a waste heat recovery system to significantly improve energy efficiency.
Modular and Customized Design Capability
Core equipment adopts modular prefabrication, supporting rapid deployment (installation cycle shortened by 50%) and adapting to diverse scenarios such as offshore platforms, onshore gas fields, and LNG pre-treatment.
Can customize single-tower, double-tower, or multi-tower parallel systems according to customer needs, with a treatment capacity ranging from 10,000 to 1,000,000 Nm³/d, flexibly matching gas fields of different scales.
Intelligent Control and Remote Operation & Maintenance
Equipped with a PLC+IoT intelligent control system to monitor key parameters such as pressure, temperature, and dew point in real time, supporting fault early warning and automatic adjustment.
Optimizes the adsorption-regeneration cycle through cloud-based big data analysis, extending the service life of molecular sieves and reducing operation and maintenance costs by 10%-15%.
Energy-Saving and Environmental Protection Technology
Features zero-emission design for regenerated tail gas, complying with EU CE, US EPA, and other environmental standards.
Energy consumption is 25%-40% lower than that of traditional Triethylene Glycol (TEG) dehydration systems, helping customers achieve carbon emission reduction goals.
Long-Cycle Operation Reliability
Molecular sieves adopt anti-pulverization coating technology, with a service life of over 5 years, reducing replacement frequency.
Key components (such as valves and instruments) are selected from international first-tier brands (e.g., Siemens, Emerson), with a Mean Time Between Failures (MTBF) of over 100,000 hours.
Strong R&D and Engineering Experience
Possesses 19+ patents for dehydration technology and software copyrights; the R&D team is led by doctors and cooperates in-depth with universities and colleges.
Has over 1,000 successful cases worldwide, covering extreme working conditions such as high-sulfur gas fields in the Middle East and low-temperature environments in the Arctic.
Product Advantage Comparison
Indicator
Yipu System
Freeze-Type
Traditional PSA
Competitor Adsorption-Type
Dew Point
-70℃ (at 10MPa)
+3℃
-40℃ (atmospheric pressure)
-60℃ (service life only 2 years)
Residual Oil Content
≤0.001 ppm
≤1 ppm
No oil removal function
≤0.01 ppm
Energy Consumption
0.08 kWh/Nm³ (comprehensive)
0.1 kWh/Nm³
0.25 kWh/Nm³
0.18 kWh/Nm³
Pressure Adaptability
0.5-10MPa lossless operation
Requires pressure stabilization to 0.7MPa
Only applicable for 0.5-0.8MPa
1-6MPa
Service Life
8 years (molecular sieve)
No consumables
5 years (frequent replacement required)
3 years
Typical Case
Project Name: Ultra-High Purity Nitrogen Project in a 12-Inch Wafer Fab
Working Conditions
Treatment Capacity: 8,000 Nm³/h, pressure 5MPa
Requirements: Dew point ≤ -65℃, oil content ≤ 0.001 ppm
Results
Stable dew point of -68℃, oil content of 0.0003 ppm
Wafer oxidation defect rate reduced from 3% to 0.02%
Economic Benefits
Annual electricity cost savings of 4.2 million RMB
Reduced annual wafer scrap losses by 180 million RMB
