What Is On-Site Liquid Nitrogen for Livestock Farms?

The on-site use of liquid nitrogen for livestock farming involves either generating the gas directly on the farm or receiving a large amount of liquid nitrogen from a supplier and then storing that gas locally. The type of on-site liquid nitrogen used will depend upon the specific needs of each individual farming operation.

Liquid nitrogen is commonly employed by animal breeders as a cooling agent when preserving frozen semen and other biological specimens. As such, it is a key component of standard preservation techniques which require a low temperature environment. In addition, the use of liquid nitrogen allows for successful implementation of breeding programs based upon consistency in accessing stored genetic material.

A livestock farm does not necessarily need an in-house production facility. For example, if a dairy operation uses frozen semen only for periodic artificial insemination then they should consider buying a suitable storage container and developing a dependable replacement strategy. On the other hand, if a large breeding operation is constantly processing semen and consuming large quantities of liquid nitrogen, there would be a more compelling reason to assess the potential for in-house production.

Production Is Different from Storage

A single system for producing liquid nitrogen could be composed of more than one individual function.

l Nitrogen generation or supply: Provides nitrogen gas suitable for processing.

l Gas pretreatment: Removes contaminants that could affect downstream equipment.

l Nitrogen liquefaction: Cools nitrogen gas until it becomes liquid.

l Cryogenic storage: Holds the liquid nitrogen before use.

In general, a nitrogen generator will only create nitrogen as a gas and not in a liquid state. For farms looking at making their own nitrogen, they need to ensure the proposed equipment has the capability to produce liquid nitrogen.

Many farms may find that the best way to handle their storage needs is through a combination of properly sized cryogenic storage, regularly scheduled delivery, and an emergency supply plan.

Why Do Livestock Farms Need Liquid Nitrogen?

Liquid Nitrogen assists with many of the processes that relate to breeding animals and managing genetic resources. How liquid nitrogen is used by a farm will depend upon what type of business it has.

2.1 Frozen Semen Storage

Artificial insemination programs frequently employ frozen sperm obtained from selected breeding male animals. Frozen sperm is kept in a low temperature environment created with liquid nitrogen for preservation according to predetermined guidelines.

A dependable source will allow farms and breeding establishments to keep an adequate amount of semen available for use in future insemination processes. Regardless of whether a farm or breeding facility has a dependable source of semen, staff must adhere to proper sample handling, storage, and identification protocols.

The WOAH provides specific guidance regarding the collection, processing, storage, and cryogenic tank management of semen. The WOAH's recommendations include but are not limited to, maintaining the correct storage condition, properly identifying each individual sample, and utilizing proper handling techniques.

2.2 Artificial Insemination Services

Large scale farms as well as agricultural service providers will likely deliver frozen semen to many different sites. In order to be able to successfully manage their supply chain of frozen semen, these companies must have a well thought out plan in place for resupplying their storage containers, tracking what is on hand, and moving product from point A to point B.

If there is enough demand, then the use of on-site liquid nitrogen production will help facilitate this process. The worth of on-site liquid nitrogen production depends upon the total supply chain; i.e., reliability of production, storage capability, transportation needs, and available personnel.

2.3 Breeding Research and Genetic Preservation

Some animal housing units collaborate with researchers and/or animal genetic resource program developers. The collaboration can result in preserving biological material from the animals housed at these locations for use in research, breeding development, and conservation.

Preservation protocols differ for each species and sample type. Planning the liquid nitrogen supply must therefore be coordinated with either the veterinary or laboratory team that will manage the specimens.

2.4 Reliable Farm Operations

On site, a properly designed setup will minimize the frequency of deliveries. If you are located at a distance from your industrial gas provider, there is a possibility that you will experience delivery delays and/or incur significant delivery charges.

The use of self-production however does introduce other aspects such as equipment maintenance, energy use, training for employees and possible times of being down. Before farms decide to invest in self-production they need to consider both what will be gained from doing so and what they will have to deal with.

How Does On-Site Liquid Nitrogen Production Work?

On-site systems must produce acceptable nitrogen gas, convert that gas into liquid nitrogen, and then store the resulting liquid nitrogen in a safe manner until such time as the liquid nitrogen is required.

Step 1: Supply or Generate Nitrogen Gas

The system will obtain nitrogen gas through either a separate gas supply system or by using a nitrogen generator specifically designed for use in this project.

For a farm-based application, the gas supply must meet the liquefaction unit's requirement for gas purity, pressure, flow rate, and quality.

Step 2: Pretreat and Purify the Gas

The type of pretreatment required depends on both how the system was designed and what kind of gas will enter it. In order to safeguard against damage to equipment that is downstream from the pretreatment system, additional steps such as filtration, drying, etc., can also be necessary.

The farm needs to ask its equipment provider for the written specifications of the feed gas that will be used by the system. This will help the farm figure out if the proposed system will work with the farm's utility systems and the operating environment.

Step 3: Liquefy the Nitrogen

A cryogenics unit changes the state of a gas such as nitrogen from a gas to a liquid. To do this, specialized refrigeration units and heat exchangers are used.

The rate of production is determined by the design of the system and the condition under which it will operate. Therefore, when evaluating the rated output you need to consider how well the system is likely to perform based upon what you expect the system to experience at your site, as well as the expected load.

Step 4: Store the Liquid Nitrogen

A compatible cryogenic storage vessel is used to hold the liquid nitrogen. Daily consumption, variations in production, maintenance time frames, and the necessary backup amount should be taken into account when determining how much space will be needed to store the liquid nitrogen.

A storage vessel is different from a production facility. Farms who are buying liquid nitrogen only require storage and transfer equipment, whereas those farms who wish to produce their own will have to consider both production and storage facilities.

Step 5: Transfer and Monitor the Supply

Liquid nitrogen is transferred into the correct receiving vessels with compatible equipment and by following the established procedures. Additionally, liquid nitrogen transfer monitoring devices can be used to monitor the level of the nitrogen in the vessel being filled, as well as its operating parameters and any alarm conditions that occur.

A dependable system would additionally feature well-defined procedures for handling situations such as low inventory levels, equipment breakdowns, regular maintenance, and immediate replacement of parts.

Which Farms Should Consider On-Site Production?

On-site liquid nitrogen production is not appropriate for all livestock operations. Those operations that have a demonstrated need for liquid nitrogen and a sound business plan are the most likely candidates.

Small and Medium-Sized Farms

Small farms could find it easier to use delivered liquid nitrogen rather than owning and operating their own liquid nitrogen production facility. The reason being, the small farm's need for liquid nitrogen would likely not be large enough nor consistent enough to warrant the cost of purchasing and maintaining the equipment required to produce the liquid nitrogen.

A proper storage container, regular inventory reviews, and reliable suppliers could suffice.

Large Farms and Breeding Centers

Facilities that experience a constant demand for liquid nitrogen need to evaluate if purchasing liquid nitrogen is more economical than producing it on-site. The evaluation process should take into account all expenses associated with on-site production including; electricity, the percentage of time the facility produces liquid nitrogen (plant utilization), maintenance of equipment, labor costs, storage capacity, and whether or not there will be a need to purchase additional liquid nitrogen to meet demands.

At even a very large facility, there is nothing that says producing your own product locally will always be the most economical option. It is possible that you could have a nearby supplier who offers better prices and more dependable delivery services.

Remote Farms

Self-production may be a better option than purchasing from a distant location due to potential limitations on how often items can be shipped to your location, and/or the cost of shipping to your location. When you consume the item regularly, self-production becomes even more appealing.

However, remote farms will have to take into consideration how they can reach their technician when needed; whether there are any spare parts available for use in the event of failure; and if emergency support services can be accessed. A plant which has difficulties being maintained may provide an additional source of risk in terms of supply.

What Equipment Does a Farm Need?

The type of machinery that is needed is based upon whether the farmer desires to create liquid nitrogen, or if he/she only wants to receive and store it.

5.1 Nitrogen Generation System

Before choosing a specific piece of equipment, the farm must determine what its requirements are with respect to purity, flow rate, pressure, and the quality of the gas that will be generated.

A separate liquefaction stage will be required to produce liquid nitrogen from the proposed system that only generates nitrogen gas.

5.2 Nitrogen Liquefaction Unit

The main component of the liquefaction unit converts a usable amount of nitrogen gas to a liquid. The size of this component will depend upon the projected consumption rate on the farm and the proposed daily operational hours.

Buyers need to take into account the rated output, what the operating conditions are like, how much power is used by the equipment, how often it needs maintenance, and the performance claims made by the manufacturer.

5.3 Cryogenic Storage Tank

The volume of the storage vessel for liquid nitrogen depends upon several factors. These include how much liquid nitrogen is consumed, the rate of filling the vessel, the reliability of the production process, and the amount of liquid nitrogen needed to maintain a safe level.

A farm should choose a tank based on more than just the nominal volume. The farm will need to take into account how it plans to install the tank, if the connections are compatible with other equipment on the farm, the design pressure of the tank, the type of insulation being used, and if there is enough space for the operator to safely operate the tank.

5.4 Transfer and Filling Equipment

Liquid Nitrogen can be moved from one type of container to another (i.e., storage to receipt) using appropriate equipment for transferring the product. There are many configurations that will work based upon the rate at which you wish to make the transfer, the layout of the area where you intend to perform the transfer, and whether or not the containers are compatible with each other.

Do not improvise on how you will be transferring materials. Materials and methods used for transferring must be able to handle cryogenic services and have been approved for the use intended.

5.5 Monitoring and Control Equipment

The use of monitoring will allow operators to recognize when there are issues with low stock levels, unusual operating circumstances, or hardware failure. Depending on the type of monitoring system being utilized, the operator may be able to monitor liquid level measurements, temperatures and pressures, alarms, and control interfaces.

As important to a farm as the tools used, is a set of easily understood, and operating instructions. All employees must understand which employee will monitor the system, how frequently data will be recorded, and what to do if an alarm goes off.

On-Site Production vs. Purchased Liquid Nitrogen

Before making any purchases of equipment, it is important for livestock producers to compare their own production capabilities of liquid nitrogen versus purchasing liquid nitrogen from an outside source.

When Is On-Site Production Worth Considering?

The on-site production of liquid nitrogen can be an attractive option for farms that use a large amount of liquid nitrogen consistently and have issues with the logistics of obtaining it from outside sources.

The benefits of using this method of centralizing breeding facilities can also assist with coordinating production and storage. However, there are many factors that need to be weighed when considering whether to use a centralized breeding facility. Some of these include the cost of the facility itself, how much power will be used in the facility, what type of skilled labor will be needed to run the facility, and what the risks are associated with down time.

When Is Purchased Liquid Nitrogen More Practical?

Purchased liquid nitrogen is suitable for farms that have a lower demand for it, use it infrequently, or are close to a reliable source. Purchasing liquid nitrogen eliminates the difficulty of operating a production line.

The most cost-effective option for many farms is to purchase a quantity of grain that will fit into a properly sized vessel and then agree upon a set delivery date. An additional possibility is a hybrid system where you make regular purchases of grain and have an agreement for an emergency delivery if needed.

How to Plan Capacity and Storage

Capacity planning needs to be based upon the actual demand that exists for a product rather than on an estimate. The capacity of both the production unit and the storage vessel will depend on what is needed by the farm to operate efficiently.

7.1 Record Current Consumption

Review records of liquid nitrogen purchases, amounts delivered, frequencies of refills, and current stock on hand. Attempt to separate normal consumption from abnormally high usage periods.

If there are no accurate records available on the farm, then start to collect these prior to making a significant financial commitment. Although preliminary estimates may assist with feasibility assessments, using actual measured demand will provide a more solid foundation for choosing machinery.

7.2 Estimate Peak Demand

The consumption of supplies can grow during peak times of breeding, big sample-processing projects, and/or expanding inventories. Therefore, the system should take into consideration such fluctuations.

Storage provides a means to provide a buffer for short-term imbalances between production and consumption. However, storage cannot replace having enough production capability or developing an emergency plan.

7.3 Consider Operating Hours and Downtime

The plant's production schedule determines how much capacity will be needed to satisfy customer demand. There are variations in the way that units operating continuously and those running only at specific times operate, and therefore, they may require different types of support.

In addition to considering maintenance, startup, interruption, and the period necessary to return to standard operation, request from your supplier that they provide an explanation regarding the anticipated actual output during the suggested operational hours.

7.4 Plan for Future Growth

Evaluate if the farm will grow its breeding operation, include additional storage sites, and/or expand upon utilizing frozen genetics.

Demand in the future should be planned realistically. Flexibility can be achieved through modular equipment or by phasing in investments if the planned design allows for subsequent expansion.

How to Evaluate Operating Costs

The total cost of operating a liquid nitrogen plant for the life of the plant is more than just what was paid for the plant itself. A farmer needs to consider the initial purchase price, the cost of the utility bills, the cost of hiring people to run the plant, the costs associated with keeping the plant maintained, how much it will cost to store the product, and if there are any issues that could affect whether or not they can get the product when needed.

8.1 Initial Investment

Depending on the project scope, initial costs may include:

l Nitrogen generation and liquefaction equipment.

l Gas pretreatment and purification.

l Cryogenic storage vessels and transfer equipment.

l Electrical connections and other site utilities.

l Installation, commissioning, and training.

l Required ventilation, monitoring, and safety provisions.

Obtain a clear quotation that specifies what is included and excluded. Otherwise, an initial low quote could leave out components the farm will need to buy on its own.

8.2 Energy and Maintenance

Electric power is typically one of the highest operating expenses associated with a liquefaction process. The total electricity required by the system varies significantly depending on several variables including: equipment configuration, operating parameters, production rates, and plant capacity utilization.

Maintenance cost can be broken down into scheduled services, replacing parts, using consumables, and having access to specialized assistance. It is also important for the farm to take into account the price of down-time and how easy it will be to get emergency services.

8.3 Compare the Total Cost of Ownership

A simple comparison may be able to provide insight into whether self-production would be cost-effective.

Annual on-site production cost:

l Annualized equipment and installation investment.

l Electricity and other utilities.

l Maintenance and spare parts.

l Labor and operator training.

l Storage and handling.

l Backup liquid nitrogen supply.

Annual purchased liquid nitrogen cost:

l Product purchase cost.

l Delivery and handling charges.

l Storage and transfer costs.

l Costs associated with delivery delays or emergency orders.

The assessment period should be identical to the one used in option 1 and the operating assumptions should be comparable to those of option 1. For a accurate assessment of costs, you will need to determine your local electricity rates, receive quotes from potential suppliers, estimate how much electricity you anticipate consuming, and verify that the information you have on your current system is correct.

Safety and Maintenance Requirements

Liquid nitrogen has to be handled carefully because it is so cold, and can replace oxygen in the air if allowed to evaporate from a liquid state to a gaseous state.

9.1 Ensure Adequate Ventilation

Storage and transfer locations require adequate ventilation based on the type of facility being installed and the associated risks. Particular attention should be paid to enclosed areas, as nitrogen may be able to replace oxygen within those areas without creating a noticeable odor that would alert people to the presence of a hazard.

Depending upon the design of your site, as well as what is required of you, you will need to determine whether or not it would be appropriate to install oxygen monitors and/or alarms. All safety measures that are specific to your site should be reviewed by qualified individuals.

9.2 Train Staff in Cryogenic Handling

Liquid Nitrogen causes very severe cold burns. Operators must wear the appropriate PPE (Personal Protective Equipment) for the job they are doing. This includes using PPE such as cryogenic gloves, eye/face protection, and other appropriate protective clothing.

Staff is required to use equipment according to manufacturer guidelines and the farms' written operating procedures. Training will include the normal transfer of chemicals, how to respond to a leak, alarm systems, and emergency evacuation.

9.3 Inspect Storage and Transfer Equipment

Examine tanks, pipe lines, control valves and connections for any structural damage or abnormal operations. Pressure-reducing systems must be maintained in operational status and equipment cannot be sealed so as to trap liquid nitrogen without adequate pressure relief.

Only equipment designed for cryogenic service should be used.

9.4 Maintain Storage and Sample Records

In addition to maintaining liquid nitrogen for frozen semen storage, farm employees need to keep track of sample identity, record what is stored in each location, and document when supplies are replaced.

The World Organization for Animal Health (WOAH) has recommended that all farms have a system in place to control access to semen storage areas, clearly label each sample collected, and maintain good hygiene practices within the cryotanks. Additionally, WOAH states that farms should use new liquid nitrogen to either completely fill or add to existing amounts of liquid nitrogen in the cryotanks as outlined in its semen storage guidelines. Each farm must meet the requirements of the standards that apply to its specific operation and jurisdiction.

9.5 Establish a Backup Plan

A production facility will have planned maintenance or experience unexpected downtime. A farm must set up minimum reserves, assign personnel, and obtain backup liquid nitrogen if necessary.

This is particularly critical for biological materials that are being held in storage and have a large potential for either breeding or sale. Supply chain planning should focus on maintaining the storage process, rather than just keeping the manufacturing processes functional.

How to Choose a Liquid Nitrogen Equipment Supplier

A appropriate provider will have an understanding of the farm's requirements, location, and operations. To select machinery solely on cost or claimed performance may result in selecting a machine configuration that is not adequate.

10.1 Confirm the Equipment Scope

Request confirmation as to whether the proposal includes nitrogen generation, liquefaction, storage, transfer, control systems, installation, and commissioning. When a supplier offers only a portion of the system, provide clarification regarding which party will be responsible for integrating the remainder of the equipment.

10.2 Verify Performance Specifications

Request written specifications for:

l Liquid nitrogen output under defined conditions.

l Nitrogen purity and feed-gas requirements.

l Power consumption and utility requirements.

l Recommended storage capacity.

l Installation and environmental requirements.

l Maintenance schedules and spare parts.

l Warranty, commissioning, and technical support.

These details allow the farm to compare suppliers using consistent criteria.

10.3 Check Service and Supply Continuity

Farms in remote areas need to take special care when evaluating the availability of technical assistance, the type of response plans they have, how available spare parts are, and the types of maintenance required.

10.4 Contact an Industrial Gas Equipment Provider

The Bangwin Gas Equipment is an entry point to learning more about industrial gas equipment as well as some of the requirements that you may need to complete your projects. It is recommended that buyers verify the products currently available through the company and if they are capable of providing the liquid nitrogen production system that would be required for the buyer's farm.

Visit the official website: https://bangwingascylinder.com/

When asking for a quote for equipment, include your estimated usage, where the site is located, what utilities are available, how much space you need to store items and if you require an entire production facility or just the storage and distribution components.

Frequently Asked Questions

11.1 What Is On-Site Liquid Nitrogen for Livestock Farms?

The production or supply of liquid nitrogen to a livestock facility is referred to by this term. This can be used in conjunction with applications like freezing semen for storage and other approved methods of cryogenically preserving materials. There are two primary types of systems that could fall under this definition; either an entire production plant, or a storage and distribution system.

11.2 Does Every Livestock Farm Need a Liquid Nitrogen Plant?

No. Farms with low or erratic usage of nitrogen will likely be able to buy liquid nitrogen from a supplier at less expense than they can produce it themselves. However, if there are high costs associated with transportation of purchased liquid nitrogen, if there is a high cost associated with the frequency of purchasing liquid nitrogen, or if the farm has operational constraints that require the use of liquid nitrogen, then the farm should consider installing an on-site liquid nitrogen generator.

11.3 Can a Nitrogen Generator Produce Liquid Nitrogen Directly?

A standard nitrogen generator will produce gaseous nitrogen. In order to produce liquid nitrogen, the system will need a way to cool the gas enough to turn it into liquid form. Potential customers should verify what parts are included with the purchase of the system from the manufacturer.

11.4 How Much Liquid Nitrogen Does a Farm Need?

The quantity of product needed will vary with the number of animals being bred on the farm, the current level of products in stock, how frequently the products need to be replaced, the types of transfers occurring, and the highest level of usage that may occur. Whenever possible, use actual usage data instead of estimating based upon general information.

11.5 Is On-Site Production Cheaper Than Buying Liquid Nitrogen?

The cost will depend upon the initial investment in equipment, the price of power, maintenance expenses, labor costs, how much of your facility's capacity is used, shipping costs and customer demand. A comprehensive total cost comparison based on local quotes from suppliers provides the best method for evaluating which option would be most beneficial for you.

11.6 What Storage Equipment Is Required?

The farm requires cryogenic storage tanks that can work under the specified operating environment and for the designated purpose. A thorough assessment of the storage tank's capacity, insulation, pressure rating, installation procedures and transfer methods must be performed as part of the overall system.

11.7 Is Liquid Nitrogen Safe for Farm Use?

When using liquid nitrogen, it should always be done with the proper equipment, ventilation, training, personal protective equipment (PPE), and emergency response plans established. While liquid nitrogen is capable of causing extremely serious cold burns, it also creates an atmosphere that lacks oxygen, which poses a danger if used in poorly-ventilated areas.

11.8 How Can Farms Prevent Supply Interruptions?

Track your stock, set up when you will order more products, make sure your machines are being worked on as per what the manufacturer said, and find other ways to get the stuff you need if you run out. Farms that protect important biological materials should have clear jobs and action plans for emergencies before they happen.

Conclusion

For livestock farms that require a consistent source of liquid nitrogen for their artificial insemination program and other related activities (e.g., storage of frozen semen), having on-site production of liquid nitrogen may be the most cost-effective approach. But, while an on-site production facility may make sense in some situations, it isn't always the best choice.

A proper decision will be based upon: actual consumption, availability of delivery services, the amount of money spent to buy a system, cost of electrical power used to operate the system, capability to service/maintain the system and how important it is to have continuous supply. For small operations (farms) it might make sense to purchase liquid nitrogen; however, larger and/or more isolated operations/facilities may find it makes more sense to look at producing their own on-site.

Before you purchase any equipment for your system, make sure to consider the entire system. This includes the equipment used to generate nitrogen, freeze products, store products at low temperatures, move products from one area to another, and control potential safety risks. In addition, when selecting the best equipment for your farm, base your decision on well-documented performance records as well as a realistic assessment of the total costs involved in purchasing and operating the equipment.

To learn more about Industrial Gas Equipment, go to Bangwin Gas Equipment.