LPG Air Blender — SNG Backup System for Industrial Gas Supply
GasGenix designs and manufactures industrial LPG air blenders — precision gas mixing systems that produce Synthetic Natural Gas (SNG) from liquefied petroleum gas (LPG) and compressed air. Furthermore, SNG produced by our systems is fully combustion-interchangeable with natural gas. As a result, industrial facilities can switch from natural gas to SNG backup supply without burner replacement, reconfiguration, or production interruption.
Our LPG air blender systems comply with EN ATEX and PED directives. Moreover, GasGenix is a member of the Polish Gas Chamber of Commerce (IGG) and leads two standardisation working groups for gas blending technology. Therefore, our systems are built to the highest engineering standards in the European gas industry.
What Is SNG — Synthetic Natural Gas?
Synthetic Natural Gas (SNG) is produced by blending LPG (propane or butane) with compressed air in a precisely controlled ratio. Specifically, the blending ratio is calibrated to achieve a Superior Wobbe Index (Ws) equivalent to natural gas — typically 49–56 MJ/Nm³ (and more!) for H-gas specification.
The key engineering formula is: NG = SNG (LPG + AIR) — Wobbe Index (MJ/Nm³). As a result, SNG behaves identically to natural gas at the point of combustion. Therefore, no modifications to burners, pipelines, or gas appliances are required when using SNG as a natural gas substitute or backup.
Furthermore, SNG can be produced from bioLPG (renewable propane) instead of fossil LPG. In this case, the system produces bio-SNG — a fully renewable gas with a significantly lower CO₂ footprint. This configuration complies with EU RED III Directive 2023/2413.
Learn more: World LPG Association (WLPGA) — SNG & Industrial Applications.
How Does an LPG Air Blending System Work?
The LPG air blending process consists of five key stages:
- LPG vaporization: Liquid LPG from the storage tank is vaporized — either by a electric water bath vaporizer or a gas water bath vaporizer — and delivered as LPG vapour at controlled pressure.
- Air compression: Compressed air is supplied by an industrial screw compressor and stored in an air receiver tank. Air pressure is regulated to the required inlet pressure for the mixing system.
- Precision blending: LPG vapour and compressed air are combined in the SNG blender at a precisely controlled volumetric ratio — typically 30–60% LPG and 70–40% air. Two mass flow meters with temperature and pressure correction ensure mixing accuracy of ±1.00%.
- Wobbe Index control: The control system continuously monitors the gas quality at the outlet. Specifically, pressure and temperature sensors provide real-time data for Wobbe Index calculation. Furthermore, the system automatically adjusts the blending ratio if gas quality deviates from the target value. For example, due to changes in LPG composition (propane/butane ratio) or variations in the calorific value of the reference gas (natural gas).
- SNG distribution: The blended SNG exits at the required outlet pressure and is delivered to industrial burners, boilers, or the process gas network — exactly as natural gas would be supplied.
Types of LPG Air Blenders — Which System Is Right for You?
1. Automatic SNG Blender — High Pressure, Industrial (skid mount)
The GasGenix automatic LPG air blender is a precision, fully automated gas mixing system for industrial SNG production at high pressure and high capacity. Furthermore, it is the recommended solution for all industrial backup gas, peak-shaving, and continuous SNG supply applications.
Key technical specifications:
• Output capacity: 100 to 10,000 Nm³/h (3.8–380 MMBTU/h);
• Mixing precision: up to ±1.00% accuracy;
• Operating temperature: −20°C to +60°C;
• Operating pressure (inlet LPG and Air): 1 to 11 bar;
• Outlet pressure (SNG): 1 to 10 bar;
• Inlet connections: DN 25 to DN 200;
• Outlet connection (SNG): DN 25 to DN 300;
• Design compliance: EN ATEX, PED;
• Supported LPG types: propane, butane, bioLPG, DME (any composition);
• Control system: mass flow meters with P/T correction + electrically actuated sliding gate valves + PLC.
• Mobile: a complete skid-mounted solution
The air blender is manufactured in Poland near Warsaw and CE certified. All systems are factory-tested before delivery.
2. Venturi SNG Blender (Low Pressure, Simple Applications)
The Venturi LPG air blender uses the Venturi effect to mix LPG vapour with air at low pressure — without active flow control. Furthermore, this design is simpler, more compact, and lower in cost. However, mixing precision is lower than the automatic dynamic series.
Specifications:
• Output capacity: up to 500 Nm³/h;
• Maximum outlet pressure: up to 450 mbar;
• Application: smaller industrial processes, backup systems with stable flow rates, residential district heating.
As a result of its simplicity, the Venturi blender is ideal for installations where SNG demand is stable and relatively low. Moreover, it requires minimal maintenance. Therefore, it is a cost-effective solution for smaller-scale backup gas systems.
3. Containerised SNG Blending Station (Complete Turnkey System)
The GasGenix containerised LPG air blending station combines all key system components in a single insulated outdoor enclosure. Specifically, the container includes the LPG vaporizer, gas-fired boiler (optional), air compressor, SNG blender, pressure regulators, safety valves, control system, and instrumentation.
Advantages of containerised configuration:
• Rapid deployment — no civil works or separate building required
• Designed for outdoor operation at ambient temperatures down to −20°C
• Complete factory assembly and testing before delivery
• Reduced installation time — typically 2–3 weeks on-site
• Available with remote monitoring and control (SCADA interface)
Furthermore, the containerised station is the preferred solution for glass factories, food manufacturing plants, and industrial facilities requiring fast, reliable SNG backup deployment. As a result, downtime risk during installation is minimised.
Industrial Applications — Where Are LPG Air Blenders Used?
GasGenix LPG air blenders are used wherever reliable, uninterrupted gas supply is critical for industrial operations. Furthermore, they provide a practical solution in locations where natural gas pipeline connection is unavailable, insufficient, or too costly to build. Typical applications include:
1. Glass Factories & Ceramic Manufacturing
Glass furnaces and ceramic kilns require continuous, stable gas supply at high calorific values. A gas supply interruption causes immediate, costly production damage — including furnace cooling, glass solidification, and equipment damage. Therefore, an LPG air blender backup system is essential for operational continuity. Furthermore, GasGenix has supplied SNG blending systems to multiple glass manufacturing facilities in Europe. Specifically, reference installations include glass factories with SNG capacities up to 12,000 Nm³/h.
2. Food & Confectionery Manufacturing
Food production facilities — including grain dryers, sugar factories, and confectionery plants — use large quantities of gas for process heating and drying. Furthermore, production continuity is critical: a gas supply interruption stops production and causes product losses. Therefore, SNG backup systems are standard equipment in this sector.
3. Industrial Gas Distribution — Off-Grid Locations
Many industrial facilities are located in areas without access to the natural gas network. In these locations, an LPG air blender provides a permanent, standalone gas supply. As a result, the facility can use standard natural gas appliances and burners — without modification — powered by SNG from an on-site LPG storage and blending system.
Additionally, LPG air blenders are used during construction projects to supply gas to buildings before the main gas lines are installed. Therefore, approved natural gas appliances can be commissioned immediately.
4. Metallurgical & Steel Industry
Industrial furnaces, heat treatment processes, and metal forming operations require stable gas quality for consistent metallurgical results. Furthermore, Wobbe Index stability is critical — fluctuations in gas quality cause inconsistent heating, product defects, and equipment damage. The GasGenix LPG air blender maintains Wobbe Index within ±1% accuracy at all times.
Why Choose GasGenix for Your LPG Air Blender?
- Polish manufacturer — fast delivery across Europe;
- Standardisation Working Group Leader — gas blending and biomethane conditioning standards;
- bioLPG ready — all GasGenix LPG air blenders support bioLPG as a drop-in renewable fuel, enabling immediate decarbonisation;
- 100+ completed installations — LPG, SNG, CO₂, biomethane systems across Poland and Europe;
- Full project delivery (EPC) — from site survey and engineering design through to installation, commissioning, and handover;
- Comprehensive OPEX analysis — before commitment, GasGenix provides a full cost-benefit analysis tailored to your gas consumption profile;
- CE certified, ATEX, PED — all systems comply with EU Pressure Equipment Directive and ATEX requirements for explosive atmospheres;
- Service and maintenance — GasGenix provides ongoing preventive maintenance, emergency service, and remote monitoring throughout the system lifecycle.
Main System Equipment — Complete SNG Backup System
A complete GasGenix LPG air blender / SNG backup system comprises the following components:
- LPG storage tanks: above-ground or underground, capacity 2.7 to 200 m³, suitable for propane, butane, bioLPG, or DME;
- LPG pump skid: controlled LPG supply to the vaporizer at rated flow;
- LPG vaporizer: electric water bath vaporizer (capacity up to 1,500 kg/h) or gas-fired water bath vaporizer with integrated gas boiler on a single unit (capacity up to 2,000 kg/h);
- Industrial air compressor + receiver: screw compressor with compressed air storage tank, inlet pressure 6–11 bar;
- SNG blender series: automatic LPG air blender with mass flow meters, sliding gate valves, PLC control;
- SNG buffer tank (optional): for peak shaving and emergency reserve;
- Peak shaving system (optional): for blending SNG into NG supply stream at controlled ratio;
- Containerised enclosure (optional): complete system in insulated outdoor container, operational at −20°C;
- Remote monitoring / SCADA (optional): real-time gas quality data, alarm management, remote access.
All components supplied, assembled, factory-tested, and delivered as a complete turnkey system.
Safety Features — ATEX & PED-Rated SNG Blending
Safety is fundamental in any LPG air blending system. GasGenix incorporates the following safety features in all SNG blenders:
- ATEX zone compliance: all components in the gas path are certified for use in potentially explosive atmospheres (Zone 1 / Zone 2);
- Oxygen content monitoring: continuous SIL-rated monitoring of oxygen content in the SNG mixture — automatic shutdown if the limit value is exceeded;
- Pressure safety: independent pressure monitoring on LPG inlet, air inlet, and SNG outlet — with alarm and automatic shutdown on deviation;
- Anti-dry-run protection: gas flow monitoring prevents blender operation without adequate LPG or air supply;
- Emergency shutdown (ESD): safety-related shutdown of the blending line in the event of power failure, sensor fault, or out-of-specification gas quality — control valves close to fail-safe position;
- Check valves: prevent backflow of gas between LPG and air circuits;
- CE certification: all GasGenix SNG blending systems are supplied with CE Declaration of Conformity and technical documentation for ATEX and PED.
Request a Quotation — with OPEX Analysis for Your LPG Air Blender
Contact GasGenix for a professional assessment of your LPG air blender requirements. We provide a comprehensive OPEX and energy performance analysis — tailored to your specific gas consumption, LPG supply conditions, and installation site parameters. Furthermore, our quotations include a full technical specification, equipment list, and project delivery timeline.
To receive your quotation, please provide:
- Total installed thermal power of all burners/appliances to be supplied with SNG (kW or Nm³/h – reference gas – natural gas);
- Required outlet gas pressure (bar);
- Target Wobbe Index or heating value of reference gas (natural gas);
- LPG composition (e.g. 95% propane / 5% butane, or bioLPG);
- Installation location — outdoor / indoor / containerised;
- Minimum ambient temperature at the installation site (°C).