What Is Synthetic Natural Gas
Definition and Composition
Synthetic Natural Gas (SNG) is a man-made fuel that works just like regular natural gas. It is mostly methane (CH₄). People make it by changing hydrocarbon materials through chemical or physical steps. One common way is to take LPG or vaporized LNG and mix it carefully with air or inert gases so the final gas behaves exactly like pipeline natural gas.
How SNG Differs from Natural Gas
Both fuels burn the same way in furnaces, boilers, or turbines. The big difference is where they come from. Normal natural gas is pumped out of the ground. SNG is built with small plants or mobile units. Factories far from pipelines love this because they can store the fuel as liquid, move it easily in tanks, and turn it back into gas the moment they need it.
Common Industrial Applications
Steel mills, glass factories, ceramic kilns, paper plants, and chemical sites use SNG every day. When the main pipeline has problems or shuts down for repair, SNG kicks in right away ensures high reliability and continuous operation under normal conditions. It also helps when everyone uses a lot of gas at the same time, such as on very cold winter days.
The SNG Production Process
Selecting Hydrocarbon Inputs
Everything starts with picking the right starting material. Most plants choose LPG because it is easy to buy, the price does not jump around too much, and trucks can deliver it anywhere. Some places use LNG instead, especially if they already have LNG tanks for backup power. Good feedstock keeps the whole system running smoothly.
Gas Vaporization
Liquid fuel must become a gas before mixing. Special units do this job. For LPG, the storage and vaporization unit heats the liquid propane and butane just enough so it turns into vapor. For LNG, a different unit warms the super-cold liquid until it becomes a gas again. These units keep the pressure steady so the flow never drops.
Principle of SNG Production
The core of SNG lies in mixing a small amount of LPG with a large amount of air in a strictly controlled ratio. Since the explosive limit of LPG in air is approximately 2%–9%, the system must precisely control the mixing ratio, maintain stable calorific value, and ensure safe use.
Gas Blending Skid and Mixing Process
The heart of any SNG plant is the gas blending skid. This is one big steel frame that holds filters, mixing chambers, pressure regulators, flow meters, and lots of sensors. Vaporized LPG flows in one side, air comes in the other, and they meet inside the chamber. The Okay Energy Calorific Value Control System watches the flow second by second. It can produce high-quality, stable calorific value SNGs, with flow rates that can be flexibly configured according to factory needs (e.g., 1,000–20,000 Nm³/h). The final gas meets every local standard for burners and engines.
Key Applications of Synthetic Natural Gas
Backup Fuel Supply
When a pipeline breaks or the gas company cuts pressure, factories cannot wait. SNG plants switch on in minutes. Modular peak-shaving stations and fast LPG vaporizers keep the steel furnaces hot and the chemical reactors running without a single pause.
Peak Load Shaving for Utilities
On the coldest days of the year, cities use much more gas than the pipelines can carry. Portable SNG units help the power company fill the gap. They turn stored LPG into gas and feed it into the local network so lights stay on and homes stay warm.
Off-Grid Energy Solutions
Mining camps high in the mountains, new factories waiting for a pipeline, or islands far from the mainland all need energy now. Mobile LPG vaporization skids and small SNG modules arrive on trucks. Units that handle 1,000 to 6,000 kg/h give steady gas for generators, kilns, or boilers until a permanent line is built.
Advantages of Using SNG
Flexibility in Fuel Supply
A factory does not have to sit next to a big pipeline anymore. Managers can set up SNG units wherever they need them, add more tanks when business grows, or even move the whole plant to a new site. In countries where natural gas is hard to get, SNG keeps factories open and families warm.
Cleaner Combustion
SNG combustion produces a blue flame with virtually no smoke, low sulfur, and low particulate matter, meeting stringent environmental regulations and improving air quality in the plant area. A Steel plants that switched from heavy oil to SNG cut their particulate emissions by more than half in the first year. The air around the factory gets better, and the company pays less in pollution fines.
Cost-Effective Alternative
Building a new pipeline across mountains or under the sea costs billions and takes years. A skid-mounted SNG plant costs only a small part of that and starts working in weeks. Many factories recover the money they spent on the SNG system in less than three years just from lower fuel bills and no downtime.
Technological Innovation by Okay Energy
Automated Control Systems for Mixing
Every Okay Energy blending skid runs with a PLC that talks to the factory computer through Modbus. Operators see live numbers on a screen and change settings with a few clicks. The system fixes small problems before anyone notices.
Safety Features and Monitoring Tools
Red emergency shut-off valves close in less than a second if something looks wrong. All critical components of the SNG system are designed for explosion-proof operation, including the control box, valves, and pressure sensors, and are manufactured according to international explosion-proof standards (such as ATEX/IECEx). A PLC dual-circuit interlocking and automatic shut-off system ensures safe operation of the gas mixture under all operating conditions. Plants in China, the Middle East, and Europe trust these safety systems every day.
Modular SNG Solutions for Small to Medium Facilities
Okay Energy delivered a modular system to Pake Steel Mill Company, designed to provide stable mixed gas for industrial combustion and SNG applications. The system offers a processing capacity of approximately 6,000 Nm³/h and operates at a pressure of 0.2 MPa. Built on a skid-mounted, modular design, it enables rapid on-site deployment. Once connected to pipelines and power, the unit automatically blends LPG with air (or other low-calorific gases) through proportional flow control to ensure consistent calorific value and stable combustion performance. This type of system is ideal for small to medium industrial facilities such as steel mills, manufacturing plants, or remote industrial sites where pipeline natural gas is unavailable. It delivers flexibility, safety, and cost efficiency—making it a practical option for SNG production, gas calorific value stabilization, or serving as a reliable backup fuel source.
Conclusion
Synthetic Natural Gas gives factories a practical way to get clean, steady fuel even when pipelines are far away or broken. Small plants built on skids make the gas right where it is needed. They start fast, grow when the factory grows, and burn much cleaner than coal or oil. For backup power, peak demand, or places with no pipeline at all, SNG has become a real lifesaver in modern industry.
FAQ
Q: What is the main difference between synthetic natural gas (SNG) and conventional natural gas?
A: Regular natural gas comes straight from wells deep underground. SNG is made on purpose by mixing LPG or LNG with air, so it acts the same way. Both work fine in the same burners and engines.
Q: Can I use existing natural gas appliances with SNG?
A: Yes. The Okay Energy calorific control system adjusts the mix so the heat value matches exactly what your local appliances expect.
Q: What are the environmental benefits of using SNG?
A: It burns much cleaner than coal or heavy oil. You get far less smoke, almost no sulfur, and tiny amounts of ash. Many factories now meet strict air-quality rules just by switching to SNG.
Q: How fast can an Okay Energy system be deployed?
A: Most units arrive already built on skids. Hook up the pipes and power, and the plant can make gas in a few days instead of waiting months for big construction.
