When it comes to gas storage solutions, innovation is at the heart of what we do. This ethos led us to explore how our multiple cylinder package (MCP) could enhance our own operations. The results have been remarkable, yielding significant time and cost savings, improved operational efficiency, and reduced gas wastage.

Pioneering innovation in gas storage

Since 1958, Luxfer has continuously innovated, introducing new products and exploring diverse markets. While in the development stages of our G-Stor® Hydrosphere offering, our design team identified a gap in the market for storing and transporting smaller quantities of gas. This insight led to the creation of the G-Stor® Pro Bundle – an MCP engineered to meet this demand.

The G-Stor® Pro Bundle consists of nine interconnected cylinders that are stacked horizontally. Due to the unique cylinder liner processing that reduces weight and increases volume, these bundles can store a larger volume of gas in a smaller footprint compared to other available options.

They incorporate Luxfer’s trusted Type 3 G-Stor® H2 cylinders, which are among the highest-capacity, lightest-weight Type 3 alternative fuel cylinders in the world. These cylinders offer:

– Capacity: Cylinders range from 150 to 322 litres, with storage capacities from 32.1kg to 84.3kg. 

– Efficiency: The Type 3 technology ensures zero gas wastage. 

– Durability: The cylinders are robust, designed for fast-filling, and provide zero permeation, increasing the asset value of the entire system. 

The system is set in a lightweight, durable, high-strength frame that can be seamlessly slotted into an existing structure and onto trucks and trailers, making it an ideal solution for transporting gases by road or rail. These bundles provide consistent flow rates and pressures, eliminate cylinder changeovers, and reduce gas wastage. They also offer a reliable onsite gas storage solution, ensuring continuous operations for critical applications such as industrial processes or backup power systems.

Putting our MCPs to work

To demonstrate the real-world advantages of the G-Stor® Pro Bundle, we integrated two MCPs into our Nottingham facility to supply nitrogen to our 3,500-ton extrusion press.

“Our press uses nitrogen to produce stored energy, delivering instantaneous power and constant speed during cylinder extrusion,” explains Alex Millward, Technical Engineering Manager. “Previously, we relied on nitrogen banks from a third-party supplier, but the system was inefficient, wasting significant amounts of gas and occupying excessive floor space.” 

Highlighting some of the challenges, Alex explains: “The system consisted of four banks of nitrogen used to charge the press, and another four banks ready to change over once the initial bundles, filled to 230 bar, reached a lower limit of approximately 100 bar. Trying to charge the press with less than 100 bar was extremely slow and inefficient. As we were essentially only using half the bundle, it meant there was a lot of wasted gas. Frequent hose connections also caused wear and tear, requiring regular replacements. Additionally, those bundles occupied precious floor space.

“Our G-Stor® Pro Bundle operates at 345 bar and holds a greater volume of nitrogen. Because of the increased pressure we can regulate down to 200 bar. Once it reaches 100 bar – the minimum pressure required to efficiently power the press – we can fill it up using our own liquid nitrogen stock, eliminating delivery wait times and gas wastage. Also, we don’t require as many cylinders occupying space on site. In theory we only ever need one bundle.”

Bundle benefits at a glance

– Cost savings: Nitrogen costs are ten times cheaper with the G-Stor® Pro Bundle compared to the previously used banks.

– Efficiency gains: The increased pressure halves press filling times, reducing each nitrogen shot from 20 to 10 minutes.

– Space optimisation: Luxfer’s own MCPs require seven times less floor space than the bundles they replaced.

– Improved reliability: Onsite refilling eliminates reliance on external deliveries.

– Simplified connections: A single hose connects directly to the MCP, reducing wear and tear and associated costs.

“The implementation of the G-Stor® Pro Bundles at our Nottingham site has not only enhanced our operational efficiency, but also exemplifies our commitment to innovation and sustainability. By leveraging our own products and showcasing the benefits they offer – cost savings, reduced wastage, and improved efficiency – we’ve demonstrated their transformative potential for organisations across various sectors,” concludes Alex.