Beschreibung
LW-33/30 Stickstoffkompressor – Ölfreier Hochleistungs-N2-Booster für industrielle Ultrahochdruckanwendungen bis 3,00 MPa
Engineered to deliver 33 m³/min at 3.00 MPa discharge pressure, the LW-33/30 is a two-stage, three-row oil-free piston nitrogen compressor designed for ultra-high-pressure nitrogen injection, gas liquefaction systems, and demanding petrochemical process applications. Zero oil contamination, heavy-duty construction, and optimized for continuous-duty operation at extreme pressure.
Produktübersicht
Der LW-33/30 nitrogen compressor represents a pinnacle achievement in our oil-free piston compressor portfolio, engineered for the most demanding ultra-high-pressure nitrogen applications in industrial gas infrastructure. With a substantial capacity of 33 m³/min und ein außergewöhnlicher 3,00 MPa Entladedruck, this unit occupies the ultra-high-pressure segment of our product range, serving applications that require nitrogen at pressures far exceeding conventional distribution levels.
What distinguishes the LW-33/30 is its vollständig ölfreier Kompressionsweg combined with the ability to deliver massive flow at extreme pressure. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. At 3.00 MPa, even trace oil contamination would be highly concentrated and extremely difficult to remove downstream, making the native oil-free design not merely advantageous but absolutely mandatory for high-purity applications.
Die Kompressorarchitektur verwendet eine zweistufig, dreireihig (二列三级) configuration that is essential for managing the extreme pressure ratio required to achieve 3.00 MPa discharge pressure. The three-row arrangement provides superior force balance and reduced vibration compared to single-row designs, while the two-stage compression ensures thermodynamic efficiency and manageable discharge temperatures. Each stage features independent intercooling, preserving the integrity of the PTFE sealing elements even under the thermal stress of ultra-high-pressure operation. The reinforced cast-iron frame and heavy-duty forged steel crankshaft are rated for a minimum service life of 120.000 Stunden gemäß den Standardwartungsprotokollen.
Technical Specifications – LW-33/30
| Parameter | Wert | Einheit |
|---|---|---|
| Modell | LW-33/30 | – |
| Muster | Zweistufig, dreireihig (二列三级) | – |
| Kapazität | 33 | m³/min |
| Entladedruck | 3.00 | MPa |
| Kompressorgröße (L × B × H) | 3160 × 1685 × 2440 | mm |
| Gewicht | 6.60 | T |
| Leistung | 350 | kW |
| Stromspannung | 6k oder 10k | V |
| Gasmedium | Stickstoff (N₂) | – |
| Schmierung | Ölfrei | – |
* Alle Spezifikationen beziehen sich auf Standardreferenzbedingungen (ISO 1217, Anhang C). Die tatsächliche Leistung kann je nach Standorthöhe, Umgebungstemperatur und Einlassbedingungen variieren.
Hauptmerkmale und technische Vorteile
1. Ultra-High-Pressure Oil-Free PTFE Sealing System
The LW-33/30 employs a proprietary selbstschmierende Kolbenring- und Führungsbandbaugruppe manufactured from ultra-high-performance PTFE composites reinforced with glass fiber, carbon fiber, and bronze particulates. This advanced material formulation achieves a coefficient of friction below 0.05 without any external hydrocarbon lubrication, ensuring the nitrogen stream remains completely free of oil contamination even at 3.00 MPa discharge pressure. At this extreme pressure, the partial pressure of any oil vapor would be approximately 10 times higher than at 0.30 MPa, making downstream oil removal practically impossible. The PTFE formulation is rated for continuous operation at temperatures up to 190°C, ensuring reliable sealing integrity under the severe thermal stress of ultra-high-pressure compression.
2. Three-Row Force Balance for Extreme Pressure Stability
Der dreireihige Anordnung mit gegenüberliegenden Zylindern of the LW-33/30 provides exceptional first-order and second-order force cancellation, reducing the unbalanced inertia forces transmitted to the foundation by over 90% compared to single-row designs. At 3.00 MPa discharge pressure, the peak gas forces on the pistons are substantially higher than in conventional compressors, making force balance a critical design consideration. The three-row configuration distributes these forces across multiple cylinders, minimizing vibration transmission and allowing the compressor to operate on a standard reinforced concrete inertia block without requiring specialized vibration isolation systems. This mechanical stability is essential for continuous-duty operation in 24/7 industrial environments.
3. Two-Stage Compression with Enhanced Intercooling
Der zweistufige Kompressionsarchitektur is thermodynamically essential for achieving the 3.00 MPa discharge pressure target. The overall pressure ratio of approximately 30:1 to 60:1 (depending on inlet conditions) is divided between a low-pressure stage and a high-pressure stage, with each stage operating at a manageable pressure ratio. A high-capacity shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 160°C and preventing thermal degradation of the PTFE sealing elements. The intercooler is oversized relative to the compressor capacity to ensure adequate cooling margin even during summer ambient conditions or marginal cooling water temperatures.
4. Medium-Voltage Drive for High-Power Industrial Integration
The LW-33/30 is driven by a 350 kW medium-voltage induction motor available in either 6kV or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The medium-voltage drive is essential for a motor of this power rating, eliminating the need for oversized low-voltage switchgear and heavy-gauge cabling that would be required for a 380V equivalent. Direct integration into industrial medium-voltage distribution networks reduces electrical infrastructure costs, minimizes I²R losses in power cabling, and improves overall energy efficiency. The motor is equipped with a robust bearing system rated for the radial and axial loads associated with high-pressure compressor operation.
Anwendungsszenarien
Ultra-High-Pressure Nitrogen Injection for Oil & Gas
In oil and gas production operations, the LW-33/30 provides high-pressure nitrogen for enhanced oil recovery (EOR), gas lift operations, and well stimulation. The 3.00 MPa discharge pressure is sufficient for injecting nitrogen into reservoirs at depths up to 2,000 meters, where formation pressures require high injection pressures to achieve effective displacement. The 33 m³/min capacity can serve multiple injection wells simultaneously through a centralized high-pressure nitrogen distribution system. The oil-free design is critical in oilfield applications because any oil contamination would alter the wettability of reservoir rock, reducing oil recovery efficiency and potentially causing formation damage.
Large-Scale Gas Liquefaction Booster Systems
In nitrogen liquefaction plants and cryogenic gas processing facilities, the LW-33/30 nitrogen booster compresses nitrogen from the liquefier vaporizer or storage system to the high pressure required for distribution, further processing, or reinjection into the liquefaction cycle. The 3.00 MPa discharge pressure is sufficient for driving nitrogen through high-pressure heat exchangers, expansion turbines, and process equipment that operates at elevated pressures. The oil-free design prevents contamination of the cryogenic equipment, where even trace oil would freeze and block heat exchanger passages, causing catastrophic process upsets.
Petrochemical Ultra-High-Pressure Process Nitrogen
In petrochemical and refinery operations, the LW-33/30 provides ultra-high-pressure nitrogen for high-pressure reactor inerting, catalyst regeneration, emergency depressurization, and pipeline pressure testing. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during all operational phases. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround campaigns. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free.
Power Generation & Turbine Inerting
Gas-fired power plants and combined cycle facilities require high-pressure nitrogen for gas turbine rotor inerting, combustion chamber purging, and HRSG (heat recovery steam generator) preservation during shutdown periods. The LW-33/30’s 3.00 MPa discharge pressure is adequate for driving nitrogen through the complex internal passages of large gas turbines and for maintaining positive pressure in HRSG tube bundles during extended outages. The high flow capacity can serve multiple turbines within a single power generation complex, reducing the number of compressor units required and simplifying maintenance logistics.
Material & Konstruktion
The LW-33/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, extreme thermal resistance, and extended operational life:
| Komponente | Material | Spezifikation |
|---|---|---|
| Zylinderblock (LP) | Grauguss | GG25 / HT250, reinforced wall thickness |
| Zylinderblock (PS) | Grauguss | GG25 / HT250, heavy-duty reinforced + ribbing |
| Kurbelwelle | Geschmiedeter legierter Stahl | 42CrMo4, Q&T, ISO 1940 G2.5 dynamisch ausgewuchtet |
| Kolbenringe | PTFE-Glass-Carbon-Bronze Composite | Ultra-high-pressure rated, self-lubricating, 190°C max |
| Reiterbänder | PTFE-Verbundwerkstoff | Kolbenführung, Verschleißschutz, Verschleißrate <0,03 mm/1000 h |
| Ventilplatten | Edelstahl | SS316, ultra-high-pressure concentric ring design |
| Pleuelstangen | Geschmiedeter Stahl mit Gleitlagern | Heavy-duty, precision-machined, oil-lubricated |
| Ladeluftkühler | Gehäuse aus Kohlenstoffstahl / Rohre aus Edelstahl 316 | ASME VIII Div.1, oversized capacity, 1.5× hydrotest |
| Ladeluftkühler | Gehäuse aus Kohlenstoffstahl / Rohre aus Edelstahl 316 | High-pressure finned tube, 32°C cooling water rated |
| Hochdruckleitungen | Nahtloser Edelstahl | Edelstahl 316, ANSI-Klasse 900 Flansche |
| Grundrahmen | Heavy-Duty Structural Steel | Welded fabrication, vibration-damped mounting |
Alle drucktragenden Bauteile werden in strikter Übereinstimmung mit den geltenden Bestimmungen konstruiert und gefertigt. ASME BPVC Abschnitt VIII Division 1 oder nach chinesischem GB 150-Standard. Jede Schweißverbindung wird gemäß ASME Section V, Article 2, einer Röntgenprüfung (RT) nach 100% unterzogen, und jeder fertige Druckbehälter wird einer hydrostatischen Druckprüfung mit dem 1,5-fachen des maximal zulässigen Betriebsdrucks (MAWP) für eine Haltezeit von mindestens 30 Minuten unterzogen. Hochdruck-Rohrleitungssysteme werden aus nahtlosem Edelstahl SS316 mit Flanschverbindungen nach ANSI Klasse 900 gefertigt, um Dichtheit bei einem Betriebsdruck von 3,00 MPa zu gewährleisten.
Installations- und Wartungsrichtlinien
Fundament- und Strukturanforderungen
The LW-33/30 has a dry weight of 6.60 tonnes and a center of gravity approximately 950 mm above the baseplate. The three-row opposed-cylinder design provides exceptional force balance, permitting installation on a reinforced concrete inertia block of 12–15 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz). Minimum clearance requirements: 1.5 m on the non-drive side for valve access, 1.2 m on the drive side for motor maintenance, and 2.0 m overhead for crane access during major overhauls. The high-pressure discharge piping must be properly supported with spring hangers and anchored to prevent vibration-induced fatigue at 3.00 MPa. All piping supports must be designed to accommodate thermal expansion during startup and shutdown cycles.
Auslegung des Kühlwassersystems
Der Kühlwasserbedarf beträgt ungefähr 40 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches with individual flow control valves. Given the extreme pressure ratio, the intercooler is oversized relative to compressor capacity to ensure adequate cooling margin. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS316 tube corrosion), suspended solids < 30 mg/L, and total hardness < 300 mg/L as CaCO₃. A closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended for all installations to ensure consistent cooling water quality.
Wartungsplan
| Intervall | Serviceartikel | Handlungsbedarf erforderlich |
|---|---|---|
| Täglich | Betriebsprüfung | Check vibration levels, abnormal noise, cooling water flow, discharge pressure, temperature |
| 250 Stunden | Ventilplattenprüfung | Remove and inspect suction/discharge valves for carbon deposits, spring fatigue, cracking |
| 1.000 Stunden | Beurteilung des Kolbenringverschleißes | Messen Sie das Spiel in der Kolbenringnut; ersetzen Sie die Kolbenringe, wenn das Spiel 0,20 mm überschreitet. |
| 3.000 Stunden | Zwischenüberholung | Alle Kolbenringe, Ventilkegel und Ventilplatten austauschen |
| 6.000 Stunden | Generalüberholung | Kurbelwellenzapfen prüfen, Hauptlagerspiel messen, Lager ersetzen, wenn >0,08 mm |
The oil-free design of the LW-33/30 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. The primary consumable wear items are the PTFE-Kolbenringe und -Zündbänder, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at ultra-high pressure. The high-pressure valve plates may require more frequent inspection than low-pressure equivalents due to the extreme mechanical stress at 3.00 MPa, but the overall maintenance burden remains significantly lower than oil-lubricated systems.
Konformitäts- und Sicherheitszertifizierungen
The LW-33/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Abschnitt VIII Div.1, GB 150-2011, PED 2014/68/EU Modul A
IEC 60034-1 (IE3-Effizienz), IEC 60204-1, ISO 12100 Maschinensicherheit
ISO 8573-1 Klasse 0 (Ölgehalt), unabhängig geprüft vom TÜV Rheinland
ISO 9001:2015, ISO 14001:2015
Nitrogen is classified as a simple asphyxiant gas. At 3.00 MPa discharge pressure, the risk of rapid gas release and oxygen displacement is extremely elevated. All LW-33/30 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas. High-pressure discharge piping must be equipped with pressure relief valves rated at 110% of MAWP and rupture discs as secondary protection. All high-pressure piping must be designed, fabricated, and inspected in accordance with ASME B31.3 (Process Piping). Ventilation systems must maintain ambient oxygen above 19.5% per OSHA 29 CFR 1910.146. Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic isolation at 18.0% O₂ (hard shutdown). Personnel must be trained in ultra-high-pressure gas safety protocols before operating or maintaining this equipment. High-pressure nitrogen systems must be clearly labeled and physically separated from low-pressure areas.
Leistungs- und Effizienzanalyse
The LW-33/30 achieves a specific power consumption of approximately 10.61 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the ultra-high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is highly competitive and significantly superior to diaphragm compressors, which are the primary alternative for oil-free ultra-high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 11.5–13.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the LW-33/30’s efficiency advantage versus less efficient alternatives yields approximately 200.000–400.000 kWh jährliche Energieeinsparung. At $0.08/kWh, this represents $16,000–$32,000 in direct electricity cost reduction per year. However, the primary economic justification for the LW-33/30 is typically the Eliminierung von ölbezogenen Verbrauchsmaterialien und Vermeidung nachgelagerter Ölentfernungsanlagen that would be mandatory with lubricated alternatives. At 3.00 MPa, the energy penalty of downstream oil-filtration systems (coalescing filters, activated carbon adsorbers, oil monitoring instrumentation) would consume 5–8% of the compressor’s power output—an additional 28–56 kW of parasitic load that the LW-33/30’s oil-free design eliminates entirely.
Der Gesamtbetriebskosten für die Ultrahochdruck-Stickstoffkompression is reduced by an estimated 25–35% over a 10-year operational life when the oil-free LW-33/30 is compared to lubricated systems with full downstream purification. This TCO advantage is driven by lower energy consumption, elimination of oil consumables, reduced maintenance labor, and higher equipment availability.
Anpassungs- und OEM-Fähigkeiten
We offer extensive customization options to adapt the LW-33/30 to specific site conditions, integration requirements, and end-user specifications:
- Auf Kufen montierte, schlüsselfertige Pakete: Pre-assembled compressor, motor, intercooler, aftercooler, high-pressure discharge piping, instrumentation, and control panel on a structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces commissioning risks and field installation time by 60%.
- Konfigurationen von Gefahrenbereichen: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection, automatic ventilation interlocks, and explosion-proof instrumentation can be incorporated into the control system.
- Erweiterte Prozesssteuerung: Optional Siemens S7-1200 or Allen-Bradley CompactLogix PLC with 10-inch HMI touchscreen, remote monitoring via Modbus TCP/IP or OPC-UA, and seamless DCS/SCADA integration. Ultra-high-pressure safety interlocks including automatic unload on overpressure, emergency isolation valves, and redundant pressure transmitters.
- Umweltschutz: C5-M marine-grade coating systems for coastal or offshore installations; tropicalized electrical components for ambient temperatures up to 55°C; and IP54-rated acoustic enclosures reducing noise emission from 88 dB(A) to 74 dB(A) at 1 meter.
- OEM & Private Label: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators. Technical manuals, spare parts lists, and maintenance procedures can be supplied in multiple languages.
Kundenspezifische Konfigurationen sind erhältlich bei Mindestbestellmenge: 1 Stück. Engineering review and proposal generation typically require 5–7 business days. Standard delivery time is 14–16 weeks; repeat orders are delivered in 10–12 weeks from order confirmation.
Case Study: Gas Liquefaction Plant Nitrogen Booster Upgrade
Kunde: A cryogenic gas processing facility in the Middle East producing liquid nitrogen for industrial and medical markets
Herausforderung: The facility’s existing oil-lubricated nitrogen booster (American brand, 20 years in service) was experiencing progressive oil carryover into the high-pressure nitrogen stream feeding the liquefaction cycle. Oil contamination was freezing in the main heat exchanger, causing blockages that required monthly shutdowns for defrosting and cleaning. Each unplanned shutdown cost $45,000 in lost production, and the maintenance team was spending 30% of their time on oil-related issues. The facility needed a reliable oil-free replacement capable of delivering 30+ m³/min at 3.00 MPa.
Lösung: Wir lieferten einen LW-33/30 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel with full SCADA integration. The skid footprint was engineered to match the existing foundation, eliminating civil modifications. The three-row design provided superior vibration characteristics compared to the replaced single-row compressor, reducing foundation stress. A 5 m³ surge vessel was installed upstream to buffer pressure fluctuations from the upstream nitrogen generator.
Quantifizierte Ergebnisse nach 24 Monaten:
- Stickstoffgehalt des Öls: Reduzierung von 2,8 mg/m³ auf <0,01 mg/m³, Erreichen der ISO 8573-1 Klasse 0
- Heat exchanger blockages: Vollständig eliminiert, with zero defrosting shutdowns required
- Ungeplante Ausfallzeiten: Reduced from 12 days/year to 0 days, saving $540,000 in lost production
- Maintenance labor: Reduced by 35% as oil-related maintenance was eliminated
- Energieverbrauch: Verbessert durch 8.2% versus the replaced unit, saving $28,000/year
- Amortisationszeitraum: 1.4 years based on downtime reduction and maintenance savings alone
“The LW-33/30 has transformed our liquefaction plant reliability. Before, we were fighting oil contamination every month. Now, we haven’t touched the heat exchanger in two years. The oil-free design has paid for itself many times over in avoided downtime alone.” — Operations Director, Cryogenic Gas Processing Facility
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