Technology

Nitrogen is abundant, non-corrosive, non-flammable, waterless and is not a greenhouse gas, which makes it an ideal candidate to replace natural gas used by pneumatic devices.

Absolutely. Nitrogen has an extensive safety record in many other industries around the world, including the medical, metallurgical and food industries. Further, our nitrogen tanks are installed outside where ventilation is abundant.

Inside process buildings, where instrument and tubing leaks could result in reduced oxygen levels, operators need to only use standard monitors along with building entry procedures to minimize risks, just as they would with existing fuel gas systems.

Nitrogen is a non-corrosive, non-flammable, non-polluting gas that can replace the methane gas traditionally used at remote well sites to actuate pneumatics. We take advantage of nitrogen's natural tendency to turn from liquid back to gaseous state in order to power valves, pumps and pneumatic devices. The Kathairos system requires no onsite power and operates flawlessly in all regions and weather conditions. Why? Because when liquid nitrogen inside the tank is -320°F, the tank doesn’t much care if it’s in a –40°F polar vortex or the 120°F Texas heat – the vacuum-pulled cryogenic vessel operates the same. And because nitrogen is completely dry and there is no water vapor whatsoever in the tank, you’re never at risk of a freeze-up in your lines. Lastly, because it’s inert, unlike instrument air systems, you’re avoiding the introduction of oxygen into the system and the hazards that come with it.

Conveniently manufactured as a compact free-standing integrated system, our nitrogen storage tanks range from 265L to 5,500L and can deliver nitrogen gas at ambient temperatures at a desired volume and pressure. Our engineers and field operators survey site specifics and consult well use trends to select the right-sized tanks based on pneumatic vent requirements and optimum refill frequency. 

Every Kathairos unit is equipped with cellular or satellite telemetry, which wirelessly alerts a web-based data portal, the Kathairos app and the Kathairos distribution network when tanks require refilling. The system has no moving parts, requires no maintenance, requires no electricity and generates no onsite emissions.  Almost all system functions are automated, with operator involvement reduced to a single on/off gas supply valve.  Approved for use in all Canadian provinces and US states, our units can be rapidly deployed, relocated with ease and used to address thousands of sites.

Yes, it is highly scalable. Due to the simplicity of system installation and the ability of our manufacturing partner to ramp up production to thousands of units per month, the Kathairos system is ideally suited to efficiently and effectively address the more than 400,000 unaddressed well sites in a timeframe that meets ambitious industry targets and incoming government regulations.

With no moving parts, no outside power required, and a simple double-walled storage vessel that evaporates liquid nitrogen into gaseous nitrogen at precisely the volume and pressure required by the pneumatics, the Kathairos system can be in operation for 30 years without issue. After which, the cryogenic vessel is simply recertified for continued operation. Alternative solutions that require generators, batteries, and solar panels can depreciate quickly and result in breakdown, site downtime, and costly repairs.

The Kathairos solution is an exceptionally reliable system because it has no moving parts. and performs the same regardless of outside temperature or weather conditions, because it is a closed system. Quite simply, the system cannot fail unless the laws of thermodynamics fail first.

The Kathairos tanks are conveniently manufactured as compact free-standing integrated systems, installed on galvanized steel pallets. Our largest tank pallet measures 8.5’ x 7’ (2.5m x 2m).

Absolutely. The units are highly reliable and can easily operate in cold (and hot) weather for extended periods of time.

The supply gas pressure is controlled by a regulator, adjusted onsite to meet the user’s specific requirements. Standard delivery pressure range is 40 to 110 psig with other pressure options are available upon request.

Short duration flowrates can be as high as 165 Sm³/h (0-6000 scfh), depending on the unit. High pressure (500psig MAWP) units are also available.

The system is designed to supply nitrogen gas at near ambient temperatures under normal operating conditions. The tank is equipped with an internal/integrated exchanger that uses the outer tank as an extended fin.

Yes, our tanks come equipped with a pressure maintenance regulator which limits the tank pressure to 200-250psig, depending on the tank size.

Yes, we are happy to provide an information session to review general tank operation and safety considerations associated with the system. It doesn’t take long, however, for our producer partners to learn that the Kathairos field personnel will be the ones handling all aspect of system operation, including nitrogen refills, telemetry adjustments and any other system oversight that is required. However, our field team will give a complete overview of the system during the commissioning phase, and anytime thereafter as needed.

When stored in a cryogenic vessel, liquid nitrogen builds pressure as it becomes gas. The Kathairos system utilizes this naturally occurring phenomenon by controlling the vaporization rate of the liquid nitrogen and thereby the resulting pressure, temperature and flow of nitrogen gas. Key components of the system include a support base, liquid nitrogen storage tank, pressure-temperature-flow control, safety devices, instrumentation and cellular or satellite telemetry.

Great question, and this is precisely where our pending patent lies: the actuation of well site pneumatic devices using liquid nitrogen. Liquid nitrogen is particularly useful as it expands by 700x when it warms from its liquid state back into a gas, making it an excellent, long-lasting replacement for field gas in powering pneumatics. While many producers have experimented with nitrogen gas canisters along the way, they quickly learn that it is expensive, heavy, and requires a great deal of operator involvement. Further, the N2 gas supply doesn’t last very long, and with no fixed telemetry on canisters that are constantly being swapped out and replaced, there’s no way to measure consumption, mitigation, economics or impact, either. Liquid nitrogen and a fixed tank and telemetry system that is refilled once per month by Kathairos personnel changes all of that.

Our liquid nitrogen tanks are typically refilled once per month depending on site-specific demand requirements. The tanks are carefully and specifically sized for each location based on the volume of methane being vented prior to addressing the site, and other process conditions, pneumatic inventories and site considerations. The nitrogen usage rates may vary throughout the year due to the seasonal use of certain pneumatic devices such as methanol pumps in colder climates, or frequency of dump valve actuation in general. Likewise, if additional wells or devices are brought online, the tank size or refill frequency can be easily adjusted as needed.

As well site production volumes decrease, your instrument gas requirements also typically decline due to reduced pneumatic activity. We offer system right-sizing and will swap out your existing tank with a smaller size if necessary, to ensure that you optimize nitrogen use and maintain the lowest monthly tank rental cost possible.

The various applications and devices Kathairos’ liquid nitrogen system supports:

• Instrument gas-powered pneumatics of all kinds, including
  • Level controllers
  • Pressure controllers
  • Emergency shut down devices
  • Pressure switches
  • Level switches
  • Temperature controllers
  • Flow controllers
  • Pneumatic pumps
• Specialty applications the Kathairos solution can support:
  • Engine starter applications
  • Purge applications
  • Tank blanketing
  • Pigging applications
  • Midstream facilities

First, the tank is sized according to estimated consumption rates based on pneumatic inventories and operating conditions. Our applications engineers and project managers generally target a monthly refill cycle when modeling the site, unless the producer requests otherwise.

Upon approval from the customer, the tank order is placed, and production immediately begins at our manufacturing partner Chart Industry’s facility in Ball Ground, Georgia or Theodore, Alabama.

Tank production timeline is guaranteed to be eight weeks or less. Yes, that means from the time the customer signs off on sizing and price, the order is placed, and within eight weeks, Kathairos delivers them to the customer’s staging yard anywhere in North America. When we have local inventory available at our Field Office and Yard locations, which is a standard practice in every basin we operate in, we can often have the first batch of tanks delivered to the customer within a matter of days.

The tanks are equipped with a steel pallet base so they can be set directly on solid/level ground, with no prep work required. Some customers opt to set tanks on gravel pads, but it is not necessary.

Once the tank is set onsite, the customer completes the tie-in process by connecting the tank supply to their existing pneumatic system through the singular gas use connection.

In many cases, customers can utilize existing pneumatic lines, so the tie-in process is very simple.

At any time, Kathairos’ highly experienced engineers, project teams and field crews can offer advice and support on recommended tubing and tie-in materials and configuration, and what the process should (or shouldn’t!) cost the producer.

Once the tie-in process is complete, Kathairos personnel complete the commissioning of the tank. This includes the initial cooldown, fill, and telemetry activation, and the opening of a singular valve to initiate operation. Alternatively, depending on customer timelines and requirements, the tank can be set, commissioned and filled, and then tied in when the customer is ready.