SNG (Synthetic Natural Gas) is a manufactured fuel that closely replicates the combustion characteristics of natural gas. It is produced by mixing vaporized LPG with a precise volume of air, resulting in a gas mixture that has a similar calorific value and pressure to pipeline-distributed methane. This makes SNG an ideal LPG alternative to natural gas, especially in regions with underdeveloped energy infrastructure.

The transition to SNG does not require major changes in existing combustion equipment. Industrial burners, heaters, and boilers can operate using SNG without the need for expensive retrofitting or recalibration. This compatibility means that existing burners and gas-powered equipment do not require modifications to switch to SNG, making it a cost-effective and flexible LPG alternative to natural gas.

At the core of any synthetic natural gas system is the SNG blender, a device that combines air with vaporized LPG in a controlled manner. The main function of the blender is to ensure that the resulting gas mixture remains consistent in terms of pressure, flow rate, and energy content. This is especially important in industrial applications, where fluctuations in gas quality can result in process inefficiencies, safety risks, or equipment failure.

Industrial facilities rely on SNG blenders to:

• Ensure uninterrupted fuel supply during natural gas outages or limitations.

• Provide a main or backup power supply for manufacturing, heating, drying, or electric power generation.

• Allow distant sites or off-grid areas to function independently of gas pipelines.

By incorporating real-time sensors and automated control systems, the latest SNG mixers are enabled to adjust the LPG-to-air ratio dynamically. This ensures that the gas being delivered to industrial processes remains within tight tolerances, regardless of external temperature variations, pressure drops, or changes in demand.

A typical LPG-SNG blending setup consists of several key components working in unison. First, LPG is stored in pressurized tanks and is then converted from its liquid phase into gas using an LPG vaporizer. Once vaporized, the LPG is directed to the SNG blender, where it is mixed with ambient or compressed air at a calculated ratio.

This gas-air mixture is then passed through a blending control unit or SNG blending skid, which contains instrumentation for flow regulation, pressure monitoring, and gas quality control. The blended gas is finally delivered to the point of use via pipelines, where it fuels various industrial operations. The entire system is designed to respond instantly to fluctuations in gas demand, ensuring that the energy supply remains uninterrupted and consistent.

The implementation of an SNG generation system offers multiple advantages, particularly in environments where energy security and operational flexibility are key. The main benefits of SNG systems are:

• Fuel supply continuity. No downtime due to pipeline hindrances or gas supply shortages.

• Grid independence. Ideal for remote or temporary industrial installations.

• Environmental compliance. SNG is cleaner than diesel or coal-based alternatives.

• Operational flexibility. Easily integrated with existing gas infrastructure.

One of the most important benefits is the consistency of fuel supply. In cases where natural gas pipelines are under maintenance, facing regulatory restrictions, or disrupted by external events, an SNG system ensures that industrial operations continue without interruption.

Another significant advantage is grid independence. Remote facilities, mobile operations, and temporary industrial sites can maintain full functionality without being connected to a national or regional gas network. This is especially important for industries such as mining, construction, asphalt mixing, and seasonal processing facilities.

From an environmental standpoint, SNG systems provide a clean-burning alternative compared to diesel, fuel oil, or coal-based systems. The combustion of SNG produces fewer particulates and lower carbon emissions, which helps industrial operators comply with environmental regulations and sustainability goals.

Additionally, SNG systems allow for rapid scalability. Whether the energy demand is low or high, the system can be configured to match specific requirements without needing major infrastructure investments. This makes it an attractive solution for both new facilities and expansions of existing operations.

A fully integrated SNG blending skid serves as the operational platform for the blending process. It is typically supplied as a modular unit, pre-assembled with all necessary components such as control valves, flow meters, safety interlocks, and user interfaces. This modular design streamlines deployment and diminishes engineering and commissioning time.

The control system in the blending skid is often equipped with PLCs (Programmable Logic Controllers) that monitor all critical parameters in real-time. These include inlet pressures, flow rates, ambient temperatures, and gas composition. The system automatically adjusts the air-to-LPG ratio to maintain gas quality within defined parameters, ensuring safe and efficient operation.

Because of their compact footprint and robust construction, blending skids can be installed indoors or outdoors and can operate under a wide range of environmental conditions. They are designed for continuous use and require minimal maintenance, making them suitable for 24/7 industrial operations.

Choosing the appropriate SNG blender involves evaluating several technical parameters, including:

• Required gas output (Nm³/h or SCFH (standard cubic feet per hour)).

• LPG composition (propane/butane ratio).

• Ambient operating conditions.

• Available space for installation.

• Automation and integration level.

For high-demand applications, it is essential to ensure that the SNG blender and associated blending skid can deliver a stable gas stream without pressure drops or quality fluctuations. The selection process may also include consideration of redundancy, automation level, and remote monitoring capabilities.

Working with I-Maximum can ensure that the design, engineering, and implementation of the synthetic natural gas system are tailored to your site-specific conditions, budget, and compliance requirements.

In today’s industrial landscape, the ability to maintain an uninterrupted and high-quality energy supply is a competitive advantage. Facilities that rely on natural gas but face issues related to pipeline access, supply instability, or infrastructure limitations can benefit significantly from adopting an SNG generation solution.

With technologies like LPG-SNG blending, facilities can operate independently of external gas grids and continue their processes without interruption. The central role of the SNG blender, combined with a fully integrated SNG blending skid, ensures that the synthetic gas produced is consistent, safe, and efficient.

As more industries recognize the value of flexible and decentralized energy systems, the use of synthetic natural gas systems is expected to increase. Whether used as a primary fuel source or as a backup during outages, SNG offers a reliable, clean-burning, and cost-effective solution for modern industrial operations.