The cable and wire manufacturing industry occupies a pivotal position in the global industrial landscape and serves as a key driving force behind industry development. To ensure efficient production processes, nitrogen is widely used in both sectors. As the primary component of air, nitrogen accounts for over 78% of its composition and holds irreplaceable commercial value in industrial production. As a result, an increasing number of companies are opting to produce nitrogen on-site rather than relying on third-party suppliers. In the research, development, and manufacturing of specialized nitrogen generation equipment for the cable industry.
The principle of the PSA nitrogen generator is to separate nitrogen from compressed air to the required capacity, purity, and pressure specifications. PSA is a cost-effective alternative to cryogenic separation, Dewar’s bottles, and bottled nitrogen, thereby avoiding safety and operational issues associated with high-pressure cylinders.
When comparing PSA nitrogen generators, liquid nitrogen, and bottled nitrogen gas, the differences in cost, convenience, and efficiency become clear. Bottled nitrogen gas relies on recurring purchases, transportation, and handling costs, while liquid nitrogen requires specialized storage systems and poses higher operational risks. PSA nitrogen generators, by contrast, enable onsite nitrogen generation, ensuring continuous supply, customizable purity levels, and reduced long-term expenses, making them ideal for cable production.
Why Do Cable Manufacturers Need Nitrogen?
Cable manufacturing processes such as annealing, galvanization, coating, and curing require a controlled atmosphere to maintain product quality. Nitrogen, with its inert properties, is ideal for preventing oxidation during heating, drying, and cooling stages. By reducing oxygen exposure, nitrogen protects the copper or aluminum conductors, ensuring smooth surfaces, enhanced conductivity, and extended cable lifespan. Moreover, nitrogen dew point control reduces moisture content, safeguarding insulation performance. On-site nitrogen generation plants eliminate dependence on external nitrogen gas manufacturers, reducing logistics costs, ensuring a stable supply, and allowing flexible adjustment of purity for different cable production stages.
Applications in Cable Production
Preventing Oxidation
Oxidation of cable conductors during manufacturing degrades conductivity and surface quality. Nitrogen atmospheres prevent the formation of oxides on copper and aluminum during annealing, galvanizing, and curing. By maintaining a low oxygen concentration and controlling the nitrogen dew point, PSA nitrogen generators ensure uniform conductor surfaces and better adhesion of coatings, ultimately improving the performance and durability of the finished cables.
Improving Insulation Performance
Insulation is critical to preventing electrical failures. Moisture in the production environment can compromise insulation integrity, leading to reduced dielectric strength. PSA nitrogen generators deliver dry nitrogen with a controlled dew point, ensuring insulation materials cure in a moisture-free atmosphere. This prevents microscopic voids and defects, resulting in cables with enhanced electrical properties and longer service life.
Optimizing Galvanization Processes
In galvanization, where steel wire is coated with zinc, nitrogen is used to prevent oxidation before and during immersion in molten zinc. PSA nitrogen systems create a clean, oxygen-free atmosphere around the wire, improving zinc adhesion and surface uniformity. This leads to stronger corrosion resistance and reduced defects, making the process more efficient and cost-effective.
Enhancing Curing and Vulcanization Effects
In cable sheathing and insulation manufacturing, curing and vulcanization processes require consistent temperature and atmosphere control. Nitrogen provides an inert environment that prevents oxidative degradation of polymers and rubbers. The result is improved mechanical properties, flexibility, and surface finish of the insulation layer, meeting strict performance standards.
Reducing Moisture Content and Protecting Finished Cable Packaging
Moisture ingress during or after cable production can lead to long-term degradation, including corrosion of conductors and loss of insulation properties. PSA nitrogen generators with low dew point capabilities are used to purge moisture from cable interiors, splice joints, and packaging environments. This extends storage life and ensures cables remain in optimal condition during transport and installation.
Gas Control Standards in Cable Annealing Processes
| Conductor Type | Nitrogen Purity Requirement | Dew Point | Allowed Oxygen Content |
| Ultra-fine Copper Wire (Φ0.05mm) |
≥99.9995% | ≤ -70℃ | ≤5 ppm |
| Medium-voltage power cable | ≥99.99% | ≤ -40℃ | ≤100 ppm |
| Special alloy conductor | ≥99.999% | ≤ -60℃ | ≤10 ppm |
Features of BODA PSA Nitrogen Generators
- Remote control and operational data logging for easy monitoring and management.
- Special bypass design for lower energy consumption and enhanced system performance.
- High-efficiency carbon molecular sieve filling technology to extend service life.
- Multi-stage filtration ensures high nitrogen gas purity.
- Easy installation without special foundations, suitable for standard flat surfaces.
- Professional selection, commissioning, and overseas remote maintenance support.
- Wide range of nitrogen purity options (95% to 99.999%) and flow capacities (1–3000 Nm³/h).
- Customizable nitrogen dew point from -20°C to -70°C for different cable manufacturing needs.
The engineering application of PSA nitrogen systems in cable manufacturing must adhere to the principles of process-matched design, risk prevention, and effective management. Contact the BODA GAS TECH team for customized nitrogen generation solutions to improve cable quality and production efficiency.
