Exploring the Manufacturing Techniques and Diverse Uses of Helium

Let’s begin our journey in the fascinating world of Helium – the light, colorless, odorless, tasteless, non-toxic, and inert gaseous element that floats and makes us laugh! In this blog, we will not only explore the fascinating aspects of Helium but will also take a closer look at how it is produced and the numerous uses it has.

Helium, a noble gas that is scarce and makes balloons rise and voices go high pitched, is much more than that. But let us not stop here! In this blog, we will also discover the complex procedures that are involved in the manufacture of Helium including the extraction of the gas from natural sources, the purification process that is used to make sure that the gas is of high quality and free from any contaminants.

So, as we move through the manufacturing process, we will learn more about the various uses of Helium in today’s society. From Cryogenics to Aerospace, from Healthcare to Electronics, Helium is used in all sectors and for all purposes, which makes it an irreplaceable element in various industries and technologies.

So here we go, buckle up and get ready for a ride through the world of science and marvel as Helium takes us on a journey and makes us look at the world and universe in a different perspective.

Introduction

Helium, far from being just a party balloon filler, boasts unique properties that make it a game-changer across numerous industries. In the medical field, it's the silent hero behind MRI machines, ensuring precise scans by keeping them cool. Helium's ability to defy gravity allows airships and weather balloons to take flight, providing valuable perspectives from the sky. For welders, it's an essential shield against contamination, while its inert nature makes it the go-to gas for finding leaks in everything from cars to refrigerators.  The influence of Helium extends even further, playing a critical role in electronics production by cooling components during manufacturing.  And for researchers pushing the boundaries of science, it’s incredibly low boiling point enables groundbreaking experiments. From medical marvels to space exploration, Helium's versatility and unique properties solidify its position as an irreplaceable asset.

Manufacturing Process

• Helium gas extraction employs diverse methods, primarily extracting it from natural gas reservoirs containing methane, ethane, and propane. The process initiates with purifying raw natural gas, separating its components into pure forms. Typically, this purification involves cooling and pressurizing the gas to eliminate impurities. Following this, a separator isolates the desired Helium component from the remaining gas mixture.
• After extraction, Helium undergoes additional purification before being deemed suitable for industrial or medical use. This purification process involves passing the extracted Helium through a high-pressure liquefier, effectively eliminating any residual impurities that may compromise its intended applications. Once purified, the resulting liquid Helium is highly concentrated and free from contaminants, rendering it suitable for various industrial purposes, such as coolant in industrial processes, or medical applications like MRI scans.
• The process of extracting and producing liquefied Helium from natural gas consists of the following five steps:

1. Natural gas processing/pretreatment (removal of Hydrogen Sulphide, Carbon Dioxide, water and heavy metals)

• The pretreatment process is essential for eliminating acid gases, water, and heavy metals (such as mercury) before the gas undergoes refrigeration and liquefaction. Due to Helium's extremely low boiling point, any Helium present in the natural gas feed for LNG production is concentrated in the overhead product of a nitrogen rejection unit (NRU). This typically involves a cryogenic distillation process where Helium recovery is integrated with the NRU. Having a Helium recovery unit is preferable; otherwise, the remaining Helium is vented into the atmosphere along with nitrogen.
• Gas separation processes fall into three main categories: cryogenic processes, pressure swing adsorption (PSA), and membrane separation.
• In cryogenic technologies, separation occurs at temperatures below -65ºC, enabling up to 90% Helium recovery. These cryogenic processes are categorized into two types: multi-flash cycles and high-pressure distillation column methods.

2. Natural gas refrigeration (removal of heavier hydrocarbons if any) and liquefaction (production of liquefied natural gas)

3. Nitrogen rejection (removal of nitrogen) / Helium recovery from natural gas

• Cryogenics are utilized in LNG production plants to recover Helium from the NRU after the feed gas has been liquefied. Detailed methods for producing LNG using cryogenic processes are widely documented in other literature. Key design elements for NRUs employing cryogenics.
• Modern cryogenic Helium recovery processes are considerably more complex than the basic single-column and double-column systems previously described. The dual-column cycle, while sharing many characteristics with the double-column process, offers greater integration between the process and refrigeration streams. Depending on the local feed gas composition and available product markets, a fully integrated cryogenic process may also include the recovery of heavier hydrocarbons, fuel gas, and nitrogen fractions, alongside the extraction of crude Helium.

4. Helium upgrading and purification

• Before liquefaction, the crude Helium from the NRU must be upgraded to a concentration of at least 90%. Impurities such as nitrogen, methane, hydrogen, and occasionally neon must be removed in several stages.
• The upgrading process involves condensing the bulk components, catalytically oxidizing any trace hydrogen, separating water, carbon dioxide, and oxygen through water condensation and within a PSA unit, and finally removing the remaining traces of nitrogen in another PSA unit.
• These steps result in Helium purities that can reach up to 99.99%.

5. Helium Liquefaction

Key Industrial Applications of Helium

• Healthcare

Helium gas offers therapeutic benefits for respiratory ailments such as asthma and emphysema. Its low density allows for easier gas flow through narrowed airways, reducing airway resistance and improving ventilation for patients experiencing breathing difficulties. Conversely, liquid Helium finds application as a cryogenic coolant within the medical field.  It plays a crucial role in maintaining optimal operating temperatures for the powerful magnets used in Magnetic Resonance Imaging (MRI) and Nuclear Magnetic Resonance (NMR) spectrometers, enabling these vital diagnostic tools to function effectively.

• Electronics

Helium is very important in electronics because of its physical properties. Helium is used in semiconductor manufacturing for leak detection and as an inert gas to avoid oxidation. Helium is employed to chill thermographic cameras and apparatus utilized by search and rescue teams and medical professionals for the detection and monitoring of specific physiological functions.

• Automotives

Because of its inert nature, Helium is an invaluable resource in various automotive applications. One prominent use is in the detection of leaks within car air-conditioning systems. Given its lack of reactivity, Helium serves as an ideal tracer gas for pinpointing even the smallest leaks, ensuring the efficient operation of automotive cooling systems. Furthermore, Helium's unique properties make it a preferred choice for inflating airbags. In the event of a collision, rapid deployment of airbags is crucial for passenger safety. Helium's ability to diffuse quickly enables swift inflation, providing timely protection to vehicle occupants by cushioning them from impact forces.

• Aerospace

During every space shuttle mission, liquid hydrogen and oxygen serve as the primary rocket fuel. Following the depletion of these fuels, engineers employ Helium to purge the tanks thoroughly. Helium's inert nature ensures that it does not react with other substances, eliminating any potential risk of freezing pipes or combustion when in contact with residual oxygen traces. Therefore, utilizing Helium for tank purging guarantees the safety and efficiency of subsequent missions without compromising the integrity of the spacecraft's systems.

Market Scenario

The healthcare sector's increasing adoption of Magnetic Resonance Imaging (MRI) technology and the expanding electronics industry, particularly the demand for LED screens, are driving the Global Helium market. The growing need for ultra-low temperature freezers is expected to significantly contribute to Helium demand, suggesting a positive outlook for the market in the coming years. In essence, the reliance on Helium for advanced medical diagnostics and its expanding role in cutting-edge technologies underscore the multifaceted and evolving landscape of Helium consumption.

Helium Major Manufacturers

Key players in the Global Helium market are Exxon Mobil Corporation, Linde Plc, Air Liquide, Qatargas Operating Company Limited, Gulf Cryo, Messer Group GmbH, Renergen, Air Products and Chemicals, Inc., Gazprom, Iwatani Corporation, PGNIG SA Matheson Tri-Gas Inc., NexAir LLC, Weil Group, and Others.

Conclusion:

Our exploration of the Helium universe has shown the versatility of the gas and its importance in various sectors. From making balloons float to its applications in healthcare, electronics, and aerospace, Helium’s inertness and the ability to expand and cool at the same time make it irreplaceable. It cools superconductors, detects leaks in car air conditioning systems and purges rocket fuel tanks. In the future, there is a need to take a closer look at sustainable production and appropriate consumption to maintain a stable supply chain of Helium. Thus, as a result of innovation and conservation, Helium will remain that which takes our efforts to new heights and fuels the discovery of new frontiers.