LW-5.3/16 Stickstoffkompressor – Ölfreier Hochdruck-N2-Booster für anspruchsvolle industrielle Anwendungen

Engineered to deliver 5.3 m³/min at 1.60 MPa discharge pressure, the LW-5.3/16 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, gas cylinder filling, and specialized petrochemical inerting operations. Zero oil contamination, compact footprint, and optimized for medium-duty industrial service at elevated pressure.

Produktübersicht

Der LW-5.3/16 nitrogen compressor occupies a specialized niche within our oil-free piston compressor portfolio, engineered for applications that demand both moderate flow capacity and significantly elevated discharge pressure. With a rated capacity of 5,3 m³/min and an impressive 1,60 MPa Entladedruck, this unit bridges the gap between conventional low-pressure nitrogen boosters and ultra-high-pressure gas filling systems.

What distinguishes the LW-5.3/16 is its völlig ölfreier Kompressionsmechanismus utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, making the unit immediately suitable for high-purity nitrogen cylinder filling, pharmaceutical-grade inerting, and electronics manufacturing where even trace oil content would compromise product integrity. The native oil-free certification achieves ISO 8573-1 Klasse 0-Konformität without requiring additional downstream purification equipment.

Es ist zweistufig, zweireihig (二列二级) configuration is thermodynamically optimized for the high pressure ratio required to reach 1.60 MPa. The staged compression approach divides the total pressure burden between a low-pressure cylinder and a high-pressure cylinder, with an inter-stage cooler removing the heat of compression to maintain gas temperatures within safe limits. This thermal management is critical for preserving the integrity of the PTFE sealing elements under the demanding conditions of high-pressure operation. The compact dimensions—1947 × 1900 × 2580 mm—and manageable weight of 3,97 Tonnen make the LW-5.3/16 suitable for installations where space is at a premium.

Technical Specifications – LW-5.3/16

* 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. Hochdruck-Ölfreie PTFE-Dichtungstechnologie

The LW-5.3/16 employs a specialized selbstschmierendes Kolbenring- und Führungsbandsystem manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. This material formulation is specifically engineered for high-pressure service, achieving a coefficient of friction below 0.08 without any external hydrocarbon lubrication. The rings are dimensionally stable at temperatures up to 180°C, which is essential for managing the thermal loads associated with 1.60 MPa discharge pressure. For operators requiring high-purity nitrogen, this design delivers native ISO 8573-1 Klasse 0 Konformität, eliminating the need for costly downstream oil-filtration systems.

2. Zweistufige Verdichtung für extreme Druckverhältnisse

Der zweistufige Kompressionsarchitektur is indispensable for achieving the 1.60 MPa discharge pressure from typical inlet conditions of 0.05–0.10 MPa. By dividing the overall pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the LW-5.3/16 maintains manageable discharge temperatures per stage. A dedicated high-efficiency shell-and-tube intercooler between stages removes the heat of compression, keeping gas temperatures below 160°C even at maximum continuous load. This thermal management strategy is critical for preserving PTFE ring integrity under high-pressure conditions and extends valve plate service life by approximately 35% compared to single-stage designs attempting equivalent pressure ratios.

3. Compact Design with Robust Construction

Despite its high-pressure capability, the LW-5.3/16 maintains a remarkably compact footprint of 1947 × 1900 × 2580 mm. This dimensional efficiency is achieved through a vertically oriented crankcase design that minimizes longitudinal space requirements while providing adequate maintenance access. The main frame is cast from GG25 Grauguss with integral cooling water passages, and the two-row opposed-cylinder arrangement provides natural first-order force cancellation. At 3,97 Tonnen, the unit can be transported and positioned using standard forklift equipment, eliminating the need for specialized rigging during installation or relocation.

4. Standardmäßiger 380-V-Direktantrieb für Motoren

The LW-5.3/16 is powered by a 55 kW, 380 V, 50 Hz Drehstrom-Induktionsmotor conforming to IEC 60034-1 efficiency class IE3. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage infrastructure or step-down transformers. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the LW-5.3/16 an attractive option for facilities upgrading from high-pressure bottled nitrogen or membrane separation systems to on-site compression.

Anwendungsszenarien

Hochdruck-Stickstoffflaschen-Füllstationen

The LW-5.3/16 is ideally suited for Stickstoffzylinder-Füllvorgänge where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa. The 1.60 MPa discharge pressure serves as the primary booster stage, feeding a downstream high-pressure compressor or booster pump that achieves the final cylinder charging pressure. The oil-free design is mandatory in cylinder filling applications because any oil contamination would compromise the purity of nitrogen delivered to end-users in food processing, medical, and electronics industries. The 5.3 m³/min capacity supports filling rates of 20–30 cylinders per hour, making it suitable for medium-scale filling stations serving regional industrial gas markets.

Specialized Petrochemical High-Pressure Inerting

In petrochemical operations involving high-pressure reactors, catalyst regeneration systems, and hydrocracking units, nitrogen is required at elevated pressures for reactor inerting, catalyst preservation, and emergency depressurization. Der LW-5.3/16 high-pressure nitrogen compressor delivers the 1.60 MPa pressure necessary to overcome reactor operating pressures and maintain positive inert gas flow. The oil-free certification is critical in these applications because any hydrocarbon contamination would poison precious metal catalysts, degrade product quality, and create safety hazards in hydrogen-rich process environments.

Pharmaceutical High-Pressure Inerting & Blanketing

Pharmaceutical manufacturing facilities require high-purity nitrogen at elevated pressures for reactor blanketing, powder conveying, and sterile packaging operations. The LW-5.3/16’s 1.60 MPa discharge pressure is sufficient to drive pneumatic conveying systems that transport active pharmaceutical ingredients (APIs) between process vessels without contamination risk. The oil-free design ensures compliance with FDA 21 CFR 211.72 (equipment cleaning and maintenance) and EU GMP Annex 1 (manufacture of sterile medicinal products), where any oil contamination would render batches unfit for human use.

Electronics High-Pressure Process Gas Supply

Semiconductor fabrication facilities and electronics assembly plants require high-pressure nitrogen for wafer handling, chemical vapor deposition (CVD) chamber purging, and lead-free soldering operations. The LW-5.3/16’s 1.60 MPa pressure supports the high-flow pneumatic actuators and process gas manifolds used in advanced packaging lines. The oil-free certification is non-negotiable in electronics applications because even trace oil contamination can cause solder joint defects, delamination of conformal coatings, and catastrophic failure of sensitive optical components.

Material & Konstruktion

The LW-5.3/16 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal stability, and extended service life:

Alle drucktragenden Bauteile sind gemäß den geltenden Normen konstruiert und gefertigt. ASME BPVC Abschnitt VIII Division 1 oder den chinesischen GB 150-Standards. Jede Schweißverbindung wird einer 100%-Röntgenprüfung (RT) gemäß ASME Section V, Article 2 unterzogen, und jeder fertige Druckbehälter wird einer hydrostatischen Druckprüfung mit dem 1,5-fachen des maximal zulässigen Betriebsdrucks (MAWP) für eine Mindesthaltezeit von 30 Minuten unterzogen.

Installations- und Wartungsrichtlinien

Fundament- und Raumanforderungen

The LW-5.3/16 has a dry weight of 3.97 tonnes and a low center of gravity due to its compact vertical design. A Stahlbetonplatte von 5–6 Tonnen is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The two-row opposed-cylinder arrangement inherently cancels first-order inertial forces, minimizing vibration transmission. Required clearances: 1.0 m on the non-drive side for valve maintenance, 0.8 m on the drive side for motor access, and 1.5 m overhead for routine service.

Kühlwasserspezifikationen

Der Kühlwasserbedarf beträgt ungefähr 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Acceptable water quality: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride < 50 mg/L, suspended solids < 30 mg/L. For installations without reliable municipal water supply, a compact closed-loop cooling tower with a 0.5 m³ buffer tank is recommended.

Wartungsplan

The oil-free design of the LW-5.3/16 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes to schedule, no oil samples to analyze, no filter elements to replace, and no separator cartridges to monitor. The only consumable wear items are the PTFE-Kolbenringe und -Zündbänder, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions.

Konformitäts- und Sicherheitszertifizierungen

The LW-5.3/16 nitrogen compressor meets the following international standards and regulatory requirements:

Leistungs- und Effizienzanalyse

The LW-5.3/16 achieves a spezifischer Stromverbrauch von ca. 10,38 kW pro m³/min of nitrogen delivered at 1.60 MPa discharge pressure. While this specific power is higher than low-pressure models due to the extreme pressure ratio, it remains competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated alternatives in this pressure class typically consume 11.0–12.5 kW/m³/min, and diaphragm compressors (often selected for oil-free high-pressure service) can exceed 14 kW/m³/min.

Over an 8,000-hour annual operating cycle, the LW-5.3/16’s efficiency advantage versus less efficient alternatives yields approximately 25,000–55,000 kWh of energy savings per year. At $0.08/kWh, this represents $2,000–$4,400 in annual electricity cost reduction. However, the primary economic driver for LW-5.3/16 selection is typically the Eliminierung von ölbezogenen Verbrauchsmaterialien und nachgelagerten Reinigungsanlagen und nicht nur geringfügige Energieeinsparungen.

Der Gesamtbetriebskosten für die Hochdruck-Stickstoffkompression is dominated by maintenance labor and consumables. The LW-5.3/16’s oil-free design eliminates oil changes ($300–600/year), filter replacements ($150–300/year), separator cartridge changes ($400–800/year), and oil analysis ($100–200/year), delivering total consumable savings of $950–$1,900 annually compared to lubricated alternatives.

Anpassungs- und OEM-Fähigkeiten

We provide flexible customization options to adapt the LW-5.3/16 to specific installation constraints and end-user requirements:

• Kufenmontierte Pakete: Vormontierter Kompressor, Motor, Kühler und Bedienfeld auf einem Stahlrahmen mit Gabelstapleraufnahmen und Hebeösen. Reduziert den Installationsaufwand vor Ort auf den elektrischen Anschluss und den Kühlwasseranschluss.
• Mobile Anhängereinheiten: The LW-5.3/16 can be mounted on a road-legal trailer with integrated diesel generator and cooling system, creating a fully mobile high-pressure nitrogen supply unit for construction sites, pipeline maintenance, and emergency response.
• SPS- und Fernüberwachung: Optionale Siemens LOGO! oder S7-1200 SPS mit 7-Zoll-HMI-Touchscreen, Ethernet-Anschluss und SMS-/E-Mail-Alarmbenachrichtigungen. Kompatibel mit Modbus TCP/IP für die SCADA-Integration.
• Akustische Gehäuse: Kompakte, nach IP54 zertifizierte Schallschutzkabine, die den Geräuschpegel in 1 Meter Entfernung von 84 dB(A) auf 68 dB(A) reduziert und sich für die Installation in Innenräumen in geräuschempfindlichen Umgebungen eignet.
• OEM & Private Label: Individuelle Lackierungen, Marken-Namensschilder und lokalisierte Dokumentationspakete für Gasgerätehändler und Systemintegratoren.

Kundenspezifische Konfigurationen sind erhältlich bei Mindestbestellmenge: 1 StückTechnische Angebote werden üblicherweise innerhalb von 3–5 Werktagen erstellt. Die Standardlieferzeit beträgt 10–12 Wochen; für qualifizierte Bestellungen ist eine Expresslieferung innerhalb von 8 Wochen möglich.

Case Study: Pharmaceutical Cylinder Filling Operation

Kunde: A pharmaceutical gas supplier in Southeast Asia specializing in medical-grade nitrogen

Herausforderung: The client’s existing oil-lubricated high-pressure nitrogen compressor (10 years in service) was experiencing progressive oil carryover into the nitrogen product during cylinder filling operations. Oil contamination levels reached 1.5 mg/m³, far exceeding the 0.1 mg/m³ limit required for medical-grade nitrogen certification. The oil was also contaminating the cylinder filling manifold, requiring monthly cleaning and replacement of O-rings and seals.

Lösung: Wir lieferten einen LW-5.3/16 oil-free nitrogen compressor as the primary booster, feeding a downstream high-pressure booster pump for final cylinder charging. The unit was mounted on a custom skid with integrated intercooler, aftercooler, and a Siemens LOGO! PLC control panel. A 1 m³ surge vessel was installed upstream to buffer pressure fluctuations from the membrane nitrogen generator supplying the compressor.

Ergebnisse nach 18 Monaten:

• Stickstoffgehalt des Öls: Reduzierung von 1,5 mg/m³ auf <0,01 mg/m³, achieving ISO 8573-1 Class 0 and medical-grade certification
• Cylinder filling manifold cleaning: Ausgeschieden, reducing labor costs by $8,000/year
• O-ring and seal replacement: Reduced by 90%, saving $3,500/year in consumables
• Maintenance burden: Eine planmäßige Wartung pro Jahr versus quarterly overhauls
• Kundenbeschwerden: Null since commissioning, with nitrogen purity consistently exceeding specifications

“The LW-5.3/16 has been a game-changer for our medical nitrogen business. We no longer worry about oil contamination, and our customers have noticed the improved consistency in gas quality. The payback period was just over 2 years.” — Operations Manager, Pharmaceutical Gas Supplier

Häufig gestellte Fragen & Auswahlhilfe

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