What Is Industrial Oxygen?

Industrial oxygen is a highly purified form of oxygen gas (typically 90-99% pure) used in manufacturing, metalworking, and chemical processes. Unlike medical-grade oxygen, industrial oxygen is not subject to FDA regulations for human consumption and is specifically manufactured for technical applications.

In this guide, we’ll explain how industrial oxygen is produced and cover its main applications across different industries. You’ll then learn about the key considerations for its safe use and storage.

How Industrial Oxygen Is Produced

Industrial oxygen is mainly produced using two different methods, each with distinct advantages depending on volume requirements and purity needs.

Cryogenic Air Separation

Cryogenic air separation is the most common method for large-scale industrial oxygen production. It involves cooling atmospheric air to extremely low temperatures (around -300°F or -185°C) where oxygen liquefies. 

Here’s how the process works:

1. The air is filtered to remove contaminants.
2. The air is then compressed and cooled.
3. As the temperature drops, different components of air liquefy at different temperatures, allowing for separation.
4. Once liquefied, the components are sent to distillation columns where oxygen is separated from nitrogen and other gases based on their different boiling points.

This method creates oxygen with very high purity levels (typically 99.5% or higher), which is ideal for applications that require large volumes of high-purity oxygen.

Pressure Swing Adsorption (PSA)

Pressure Swing Adsorption is a more flexible option for smaller-scale oxygen production. PSA systems use specialized molecular sieve materials that preferentially adsorb nitrogen from compressed air while allowing oxygen to pass through.

The process alternates between pressurization phases (where nitrogen is captured) and depressurization phases (where nitrogen is released and vented), continuously producing oxygen.

PSA systems typically deliver oxygen at 90-95% purity, which is sufficient for many industrial applications while offering lower startup and operational costs compared to cryogenic systems.

To put this technology in perspective, similar adsorption principles are used in everyday products like water filters and home air purifiers, though industrial PSA systems operate at much higher pressures and scales.

Key Applications of Industrial Oxygen

Industrial oxygen is used across numerous industries to enhance process efficiency and enable specialized applications that wouldn’t be possible using regular air.

Metal Fabrication and Cutting

In metal fabrication, industrial oxygen is essential for both cutting and welding operations. Specifically, oxy-fuel cutting uses the reaction between oxygen and metal at high temperatures to create precise cuts through thick materials.

The process begins with preheating metal to ignition temperature before a stream of pure oxygen is directed at the heated spot, causing rapid oxidation that cuts through the material.

This technique lets fabricators cut through steel plates several inches thick with relative ease and precision.

For welding applications, oxygen mixed with acetylene or other fuel gases creates the intense heat needed to melt and join metals. The concentrated oxygen dramatically increases flame temperature compared to using ambient air.

Metal fabrication shops typically use oxygen in cylinders ranging from small portable units to large manifolded systems, depending on their volume requirements.

While air contains only about 21% oxygen, pure industrial oxygen allows oxy-fuel welding torches to reach temperatures up to 6,000°F (3,300°C)—hot enough to melt virtually any metal used in industrial applications.

Steel Manufacturing

Steel production is one of the largest consumers of industrial oxygen globally. Modern steel mills use oxygen injection in basic oxygen furnaces to rapidly rid molten iron of impurities like:

• Carbon
• Silicon
• Phosphorus

This oxygen-enhanced process has largely replaced older air-based methods.

When oxygen is blown into molten iron, it reacts with carbon and other impurities, forming gases that escape from the melt and slag that can be removed. This purification process is essential for converting raw iron into high-quality steel.

Oxygen usage in steel mills is measured in hundreds or thousands of tons per day, so on-site production through cryogenic air separation is the most economical option for large facilities.

Chemical Processing

In chemical manufacturing, industrial oxygen serves as both a reagent and process enhancer across numerous applications.

Oxygen is a key input for producing important chemicals like:

• Ethylene oxide
• Propylene oxide
• Various peroxides

These chemicals form the building blocks for countless consumer and industrial products.

In petrochemical operations, partial oxidation processes use precisely controlled amounts of oxygen to convert hydrocarbons into valuable intermediate chemicals.

Wastewater treatment facilities use industrial oxygen to support aerobic bacteria that break down organic contaminants. Oxygen injection can dramatically increase treatment capacity without expanding facility footprint.

The controlled oxidation environment created by industrial oxygen allows for more precise reactions and higher yields compared to air-based processes.

Glass Manufacturing

Glass production has relied on oxygen-enhanced combustion for decades to improve both efficiency and product quality.

By replacing ambient air with industrial oxygen in furnaces, glass manufacturers achieve higher flame temperatures and more complete combustion. This results in fuel savings of 20-45% compared to conventional air-fuel systems.

The higher temperature also improves glass quality by reducing defects and allowing for better heat distribution throughout the molten glass.

The environmental benefits are also noteworthy – oxygen-enhanced combustion drastically reduces nitrogen oxide (NOx) emissions since nitrogen in ambient air is a major contributor to NOx formation.

Modern glassmaking facilities often employ oxy-fuel combustion systems with specialized burners designed to optimize the benefits of industrial oxygen.

Safety Considerations for Industrial Oxygen

Industrial oxygen requires careful handling due to its role as a powerful oxidizer that intensifies combustion. While oxygen is not flammable itself, it vigorously supports combustion. Materials that might burn slowly in air will burn rapidly and at much higher temperatures in oxygen-enriched environments.

The key safety protocols to follow include:

• Equipment cleaning – common materials like oils and greases can become highly flammable or even explosive when exposed to high-concentration oxygen. This is why oxygen equipment must be kept meticulously clean and free from hydrocarbon contaminants.
• Careful storage – proper storage of industrial oxygen involves keeping cylinders away from heat sources, combustible materials, and electrical equipment. Cylinders should always be secured to prevent falling and potential valve damage.
• Adequate training – personnel working with industrial oxygen should receive specialized training covering safe handling practices, emergency procedures, and proper equipment maintenance.

Even a single spark in an oxygen-enriched environment can ignite clothing. This is why special static-dissipative clothing and tools are often required when working with high-concentration oxygen systems.

Leverage Industrial Oxygen in Your Operations

Industrial oxygen plays a vital role across manufacturing sectors by enhancing combustion processes, enabling specialized chemical reactions, and improving production efficiency. 

As manufacturers continue seeking ways to improve efficiency and reduce emissions, industrial oxygen will remain a critical component of modern industrial processes.