Dual Liquid Recovery System — Feasibility Analysis
Prepared for Tim Makool, Kool Gas LLC | Based on current fill plant loss data
August 2026 | OCYL Digital Labs Research
Executive Summary
A dual liquid recovery system captures oxygen that would otherwise be vented to atmosphere during two loss pathways: boil-off (natural evaporation from the bulk LOX tank) and transfer losses (flash gas during cylinder fills and dewar filling). The recovered gas is compressed back to fill pressure and routed to the HP manifold for cylinder fills.
For a plant of Kool Gas’s size (3,000 gallon bulk LOX), the system captures lost product and routes it back to the HP fill manifold for cylinder fills. ROI should be calculated against the retail value of recovered product (as filled cylinders), not raw LOX cost — making payback significantly faster than raw material savings alone. Contact vendors for actual pricing.
Your Current Loss Profile
Loss data loads from your tank readings above — check the Loss Tracking section for current numbers.
How It Works
1. Boil-Off Recovery
Captures gaseous oxygen that evaporates from the bulk tank due to heat ingress. Typical loss for a 3,000 gal tank: 300–600 gal/month (at 0.5–0.8% NER).
2. Transfer Loss Recovery
Captures flash gas from pump cool-down, line cool-down, and dewar fill venting. Loss: 100–500 gal/month depending on volume and batching.
Recovered GOX is compressed back to 2,200+ psig and routed to the HP fill manifold. Recovery rate: 40–70% of total unaccounted loss.
Equipment Required
| Component | Vendor to Contact |
| Vent gas collection piping & manifold | Ratermann Mfg / local cryo service |
| GOX buffer/surge tank (ASME, O2-clean) | Cryofab, Manchester Tank |
| O2-clean booster compressor (largest cost item) | RIX Industries, Bauer, Sauer |
| O2 purity analyzer | Teledyne Analytical, Servomex |
| Valves, regulators, check valves (O2-clean) | Ratermann, Sherwood, Generant |
| Controls & instrumentation | Included with compressor vendor |
| Installation, engineering, commissioning | Local cryogenic service company |
Request quotes from each vendor for actual pricing. The compressor is typically the largest single cost. Used/refurbished units may be available.
ROI Calculation
Unaccounted LOX (gal/month) = D
Recovery rate (40–70%) = R
Recovered product (gal) = D × R
Cylinder equivalent = D × R × 115.1 / 251 OX251s
Revenue recovered/month = cylinders × your sell price
Annual savings = (monthly × 12) - annual ops cost
Payback period = vendor quote total / annual savings
Key insight: Calculate ROI on retail cylinder value, not raw LOX cost. The value of recovered product sold as filled cylinders is far higher than the raw bulk LOX cost.
Boil-Off Rates (3,000 Gallon Bulk LOX Tank)
| Tank Condition | NER (%/day) | Loss/Day | Loss/Month |
| New, good vacuum | 0.3–0.5% | 9–15 gal | 270–450 gal |
| Aging (10–20 yr), adequate vacuum | 0.5–1.0% | 15–30 gal | 450–900 gal |
| Old, degraded vacuum | 1.0–2.0%+ | 30–60+ gal | 900–1,800+ gal |
Percentages are of current fill level, not total capacity. Arkansas summer heat worsens boil-off.
Lower-Cost Alternatives (Start Here)
Tier 1 — Operational Changes (No Cost)
- Batch cylinder fills — fill 20–30 in continuous runs (reduces cool-down loss 30–50%)
- Prioritize cold dewar returns — reduces dewar fill losses 30–50%
- Schedule fills after bulk delivery — keeps tank full, reduces boil-off
- Track losses rigorously — meter in vs. product out
Tier 2 — Minor Upgrades (Get Quotes)
- Vacuum jacket inspection/repair on bulk tank — can cut boil-off 50–80% — get quote from tank vendor
- Vacuum-jacketed transfer hose for dewar filling — get quote from Chart or Technifab
- LOX flow meter on bulk tank outlet for precise tracking — get quote
- Insulate bare piping between tank and fill equipment
Safety & Regulatory
OSHA 29 CFR 1910.104
Oxygen storage and handling
NFPA 50 / NFPA 55
Bulk oxygen systems & cryogenic fluids
CGA G-4.1
Cleaning equipment for oxygen service
CGA P-8.4
Safe operation of vaporizers
ASME BPVC
Pressure vessel code (new vessels)
DOT 49 CFR
Cylinder marking, testing, transport
AR State
Boiler/pressure vessel regulations
Critical: All recovery system components MUST be cleaned for oxygen service per CGA G-4.1. The compressor MUST be specifically rated for oxygen service. Standard air compressors cannot be used.
Recommended Next Steps
- Quantify current losses using KoolAI loss tracking data (above)
- Inspect bulk tank vacuum — get NER tested. Fixing vacuum may be highest ROI single action
- Implement Tier 1 changes immediately (free)
- Contact vendors for quotes: RIX Industries (compressor), Chart Industries (piping), local cryo service (install)
- Contact GAWDA (Gases and Welding Distributors Association) for peer references
- Build ROI model with actual Kool Gas numbers using the framework above
Key Vendors
Chart Industries
Bulk tanks, VJ piping, recovery skids
RIX Industries
O2-clean compressors (primary)
Bauer Compressors
HP breathing air & O2 systems
Cryofab
Custom cryo vessels, buffer tanks
Taylor-Wharton
Portable dewars, bulk tanks
Ratermann Mfg
Fill manifolds, pigtails, distribution
Equipment list and technical specifications based on industry standards for cryogenic gas recovery systems. No pricing is included — contact vendors directly for quotes. Loss rate ranges are from published CGA and manufacturer specifications. Research prepared by OCYL Digital Labs, August 2026.
