Beschreibung
LW-52/8 Stickstoffkompressor – Ölfreier Hochleistungs-N2-Booster für industrielle Anwendungen mit 0,80 MPa
Delivering 52 m³/min at 0.80 MPa discharge pressure, the LW-52/8 is a two-stage, two-row oil-free piston nitrogen compressor engineered for large-scale cryogenic air separation, high-pressure VPSA nitrogen boosting, and demanding petrochemical pipeline distribution networks. Zero lubricant contamination, continuous-duty rated, and built for 24/7 industrial reliability at elevated pressure.
Produktübersicht
Der LW-52/8 nitrogen compressor stands as a high-performance flagship within our oil-free piston compressor lineup, engineered specifically for applications demanding both substantial flow capacity and elevated discharge pressure. With an impressive 52 m³/min capacity coupled with a 0,80 MPa Entladedruck, this unit addresses the most demanding nitrogen boosting requirements in large-scale industrial gas infrastructure.
What sets the LW-52/8 apart from conventional alternatives is its vollständig ölfreier KompressionswegDie Kolbenringe und Führungsringe werden präzisionsgefertigt aus hochentwickelten, selbstschmierenden PTFE-Verbundwerkstoffen, die ohne Kohlenwasserstoffschmierstoffe auskommen. Diese inhärente Ölfreiheit gewährleistet, dass der Stickstoffproduktstrom vollständig rein bleibt. ISO 8573-1 Klasse 0 Zertifizierung natively. For operators in food processing, pharmaceutical manufacturing, and electronics fabrication, this eliminates the capital expenditure and ongoing maintenance burden of downstream oil-removal filtration systems.
Die Kompressorarchitektur verwendet eine zweistufig, zweireihig (二列二级) configuration that optimally distributes the pressure ratio across two compression cylinders. This staged approach is essential for managing the thermal loads associated with 0.80 MPa discharge pressure while preserving the integrity of the PTFE sealing elements. Each stage features an independent intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-capacity operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120.000 Stunden gemäß den Standardwartungsprotokollen.
Technical Specifications – LW-52/8
| Parameter | Wert | Einheit |
|---|---|---|
| Modell | LW-52/8 | – |
| Muster | Zweistufig, zweireihig (二列二级) | – |
| Kapazität | 52 | m³/min |
| Entladedruck | 0.80 | MPa |
| Kompressorgröße (L × B × H) | 2360 × 1655 × 2235 | mm |
| Gewicht | 6.00 | 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. Fortschrittliches ölfreies PTFE-Verbunddichtungssystem
The LW-52/8 employs a proprietary selbstschmierende Kolbenring- und Führungsbandbaugruppe manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material formulation achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating the risk of oil vapor carryover into the nitrogen product stream. For industrial gas operators, this translates to native ISO 8573-1 Klasse 0 Konformität without the capital cost, maintenance burden, or energy penalty of downstream oil-filtration equipment. The PTFE rings are specifically formulated for the elevated discharge temperatures associated with 0.80 MPa operation, maintaining dimensional stability up to 180°C.
2. Optimized Two-Stage Thermodynamic Design
Der zweistufige Kompressionsarchitektur of the LW-52/8 is thermodynamically optimized for the 0.80 MPa discharge pressure target. By dividing the overall pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor achieves a significantly lower mean effective temperature per stage compared to single-stage designs. A dedicated high-efficiency shell-and-tube intercooler between stages removes the heat of compression, maintaining discharge temperatures below 155°C even at maximum continuous load. This thermal management is critical for preserving PTFE ring integrity and extending valve plate service life by approximately 40% versus single-stage alternatives operating at equivalent pressure ratios.
3. Robuster Gusseisenrahmen mit integrierter Kräftebalance
Der Hauptrahmen ist gegossen aus GG25 Grauguss (equivalent to ASTM A48 Class 30B) with integral cooling water passages machined directly into the casting. The zweireihige Anordnung mit gegenüberliegenden Zylindern provides natural first-order force cancellation, reducing the unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs of equivalent capacity. This mechanical advantage permits installation on a lighter reinforced concrete inertia block (minimum 10 tonnes versus 15+ tonnes for single-row equivalents), significantly reducing civil engineering costs and simplifying retrofit installations in existing compressor houses where foundation capacity may be limited.
4. Medium-Voltage Motor Drive for Industrial Integration
The LW-52/8 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 eliminates the need for oversized low-voltage switchgear and heavy-gauge cabling that would be required for a 380V motor of this power rating. Direct integration into industrial medium-voltage distribution networks reduces electrical infrastructure costs, minimizes I²R losses in power cabling, and improves overall energy efficiency. For facilities with 6kV or 10kV bus systems standard in large industrial plants, the LW-52/8 offers plug-and-play electrical compatibility.
Anwendungsszenarien
Large-Scale Cryogenic Air Separation Plants
In large cryogenic ASU facilities producing 2,000–5,000 Nm³/h of gaseous nitrogen, the LW-52/8 serves as the primärer Hochdruck-Stickstoffverstärker between the cold box and the distribution header. Its 52 m³/min capacity matches the output of large-scale ASUs, while the 0.80 MPa discharge pressure provides sufficient head for long-distance pipeline distribution to downstream consumers such as integrated steel mills, petrochemical complexes, and LNG regasification terminals. The oil-free design is critical in these applications because any oil contamination would compromise the purity of nitrogen supplied to sensitive processes, particularly in semiconductor and pharmaceutical manufacturing facilities served by the same distribution network.
VPSA-Hochdruck-Stickstoff-Boosterstationen
For large VPSA nitrogen generators producing 99.5–99.9% purity nitrogen at near-atmospheric pressure, the LW-52/8 nitrogen booster compresses the low-pressure product to 0.80 MPa for high-pressure distribution. The elevated discharge pressure is particularly valuable for VPSA installations serving multiple consumers through a centralized header, where pressure losses across the distribution network can be substantial. The oil-free compression path is absolutely essential in VPSA service because hydrocarbon contamination would irreversibly poison the carbon molecular sieve adsorbent, degrading separation efficiency and necessitating costly adsorbent replacement.
Hochdruck-Stickstoffeinspritzung in der Petrochemie
In petrochemical and refinery operations, the LW-52/8 provides high-pressure nitrogen for reactor inerting, catalyst preservation, pipeline purging, and emergency nitrogen injection into process vessels. The 0.80 MPa discharge pressure is sufficient to overcome the pressure ratings of typical process vessels and reactor systems, allowing direct nitrogen injection without intermediate boosting. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround and maintenance campaigns that may span several weeks. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain hydrocarbon-free.
Steel Mill Inerting & Blast Furnace Gas Sealing
Integrated steel mills require massive volumes of nitrogen for blast furnace gas sealing, tundish inerting, and ladle metallurgy operations. The LW-52/8’s 52 m³/min capacity can serve multiple blast furnaces or continuous casting lines simultaneously through a centralized high-pressure nitrogen header. The 0.80 MPa discharge pressure provides adequate head to overcome the back-pressure of blast furnace gas systems and maintain positive sealing gas flow at tuyere level. The oil-free design prevents oil contamination of blast furnace gas, which would foul downstream gas cleaning equipment and compromise the quality of recovered blast furnace gas used for power generation.
Material & Konstruktion
The LW-52/8 is constructed from premium materials selected for nitrogen compatibility, high-pressure service, and extended operational life:
| Komponente | Material | Spezifikation |
|---|---|---|
| Zylinderblock | Grauguss | GG25 / HT250, integrierte Kühlwassermäntel |
| Kurbelwelle | Geschmiedeter legierter Stahl | 42CrMo4, Q&T, ISO 1940 G2.5 dynamisch ausgewuchtet |
| Kolbenringe | PTFE-Glas-Bronze-Verbundwerkstoff | Selbstschmierend, hochtemperaturbeständig bis 180 °C |
| Reiterbänder | PTFE-Verbundwerkstoff | Kolbenführung, Verschleißschutz, Verschleißrate <0,04 mm/1000 h |
| Ventilplatten | Edelstahl | SS316, konzentrische Ringfederkonstruktion |
| Pleuelstangen | Geschmiedeter Stahl mit Gleitlagern | Präzisionsgefertigtes, ölgeschmiertes Pleuelauge |
| Ladeluftkühler | Gehäuse aus Kohlenstoffstahl / Rohre aus Edelstahl 316 | ASME VIII Div.1, 1,5-fache Druckprüfung, 30 min Haltezeit |
| Ladeluftkühler | Gehäuse aus Kohlenstoffstahl / Rohre aus Edelstahl 316 | Rippenrohrkonstruktion, Kühlwassertemperatur 32 °C |
| Grundrahmen | Baustahl | Geschweißte Konstruktion, schwingungsgedämpfte Montageplatten |
Alle drucktragenden Bauteile werden in strikter Übereinstimmung mit den geltenden Bestimmungen 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 Strukturanforderungen
The LW-52/8 has a dry weight of 6.00 tonnes and a center of gravity approximately 900 mm above the baseplate. Thanks to the two-row opposed-cylinder design, unbalanced forces are minimal, permitting installation on a Stahlbeton-Trägheitsblock von 10–12 Tonnen. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz) to prevent vibration transmission to adjacent structures and instrumentation. 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.
Auslegung des Kühlwassersystems
Der Kühlwasserbedarf beträgt ungefähr 55 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS316 tube corrosion in the coolers), suspended solids < 30 mg/L, and total hardness < 300 mg/L as CaCO₃. For sites with marginal water quality, a closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended to prevent scale formation and corrosion.
Wartungsplan
| Intervall | Serviceartikel | Handlungsbedarf erforderlich |
|---|---|---|
| Täglich | Betriebsprüfung | Prüfen Sie Vibrationswerte, ungewöhnliche Geräusche, Kühlwasserdurchfluss und Auslauftemperatur. |
| 250 Stunden | Ventilplattenprüfung | Saug- und Druckventile ausbauen und auf Kohlenstoffablagerungen, Federermüdung oder Risse prüfen. |
| 1.000 Stunden | Beurteilung des Kolbenringverschleißes | Messen Sie das Spiel in der Kolbenringnut; ersetzen Sie die Kolbenringe, wenn das Spiel 0,25 mm überschreitet. |
| 4.000 Stunden | Zwischenüberholung | Alle Kolbenringe, Ventilkegel und Ventilplatten austauschen |
| 8.000 Stunden | Generalüberholung | Kurbelwellenzapfen prüfen, Hauptlagerspiel messen, Lager ersetzen, wenn >0,08 mm |
The oil-free design of the LW-52/8 dramatically reduces maintenance complexity compared to lubricated alternatives. There are no oil changes to schedule, no lubricating oil samples to analyze, no oil filter elements to replace, and no oil separator cartridges to monitor. The primary consumable wear items are the PTFE-Kolbenringe und -ZündbänderDiese erreichen typischerweise eine Lebensdauer von 4.000 bis 6.000 Stunden unter sauberen Stickstoffbedingungen. Die vereinfachte Wartung führt zu geringeren Arbeitskosten, einem reduzierten Ersatzteillager und einer höheren Anlagenverfügbarkeit.
Konformitäts- und Sicherheitszertifizierungen
The LW-52/8 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 (Qualitätsmanagement), ISO 14001:2015 (Umweltmanagement)
Nitrogen is classified as a simple asphyxiant gas. All LW-52/8 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas where nitrogen leakage could accumulate. Ventilation systems must be engineered to maintain ambient oxygen concentrations above 19.5% volume per OSHA 29 CFR 1910.146 (Permit-Required Confined Spaces). Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic compressor isolation at 18.0% O₂ (hard shutdown). Personnel entry procedures into enclosed compressor rooms must include portable oxygen monitors and a buddy-system protocol.
Leistungs- und Effizienzanalyse
The LW-52/8 achieves a specific power consumption of approximately 6.73 kW per m³/min of nitrogen delivered at 0.80 MPa discharge pressure. This efficiency metric is commendable for an oil-free piston compressor operating at an elevated pressure ratio, positioning the unit favorably within the 40–60 m³/min capacity class. For comparison, oil-lubricated screw compressors in similar high-pressure applications typically consume 7.0–7.8 kW/m³/min, while legacy single-stage piston designs may exceed 8.5 kW/m³/min at equivalent discharge pressures.
Over a standard 8,000-hour annual operating schedule, the LW-52/8’s efficiency advantage generates approximately 112,000–280,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $8,960–$22,400 in direct operating cost reduction per year. When combined with the complete elimination of oil-related consumables (lubricating oil, filter elements, separator cartridges, waste oil disposal, and oil analysis), the Gesamtbetriebskosten für die Stickstoffkompression wird über eine 10-jährige Betriebsdauer um schätzungsweise 20–30% reduziert.
The absence of oil in the compression path also eliminates the energy penalty associated with downstream oil-removal equipment. A typical oil-lubricated compressor of this size and pressure rating requires coalescing filters, activated carbon adsorbers, and continuous oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output. The LW-52/8’s oil-free design removes this parasitic load entirely, further improving effective system efficiency.
Anpassungs- und OEM-Fähigkeiten
We offer extensive customization options to adapt the LW-52/8 to specific site conditions, integration requirements, and end-user specifications:
- Auf Kufen montierte, schlüsselfertige Pakete: The compressor, motor, intercooler, aftercooler, instrumentation, and control panel are pre-assembled on a structural steel skid with integrated lifting lugs and anchor bolt templates. This approach reduces field installation time by approximately 60% and minimizes commissioning risks through factory pre-testing of all systems.
- Konfigurationen von Gefahrenbereichen: Für Installationen in petrochemischen Anlagen, in denen gelegentlich explosionsgefährdete Atmosphären auftreten können, sind ATEX-Zone-2- und IECEx-konforme Motor- und Elektrogehäuse erhältlich. Integrierte Gasdetektion und automatische Belüftungsverriegelungen können in das Steuerungssystem integriert werden.
- 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 integration with plant DCS/SCADA systems. Automatic load/unload control and variable frequency drive (VFD) compatibility optimize part-load efficiency and reduce mechanical wear during startup.
- Umweltschutzsysteme: C5-M-Marinebeschichtungssysteme für Küsten- oder Offshore-Installationen; tropentaugliche elektrische Komponenten für Umgebungstemperaturen bis zu 55 °C; und IP54-zertifizierte Schallschutzgehäuse, die die Geräuschemission in 1 Meter Entfernung von 85 dB(A) auf 72 dB(A) reduzieren und für Inneninstallationen ohne separate Kompressorhäuser geeignet sind.
- OEM- und Private-Label-Programme: Für Gasanlagenhändler und Systemintegratoren sind individuelle Lackierungen, Markenschilder und lokalisierte Dokumentationspakete erhältlich. Technische Handbücher, Ersatzteillisten und Wartungsanleitungen können in mehreren Sprachen bereitgestellt werden.
Kundenspezifische Konfigurationen sind erhältlich bei Mindestbestellmenge: 1 StückDie technische Prüfung und Angebotserstellung dauern in der Regel 5–7 Werktage. Die Standardlieferzeit beträgt 12–14 Wochen; Nachbestellungen werden innerhalb von 8–10 Wochen nach Auftragsbestätigung geliefert.
Case Study: Steel Mill Nitrogen Distribution Upgrade
Kunde: An integrated steel mill in Southeast Asia with two blast furnaces and four continuous casting lines
Herausforderung: The mill’s existing nitrogen supply consisted of two aging oil-lubricated compressors (European brand, 18 years in service) feeding a common 0.60 MPa distribution header. The compressors were experiencing frequent oil carryover into the nitrogen stream, contaminating blast furnace gas sealing systems and causing tundish nozzle clogging during continuous casting. Maintenance costs had escalated to $85,000/year due to oil-related repairs, and the 0.60 MPa pressure was insufficient for new high-pressure tundish inerting requirements.
Lösung: Wir lieferten einen LW-52/8 oil-free nitrogen compressor as a replacement for the primary compressor, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel with SCADA integration. The 0.80 MPa discharge pressure met the new tundish inerting requirements, while the oil-free design eliminated contamination of blast furnace gas and casting systems. A 5 m³ surge vessel was installed upstream to buffer demand fluctuations from the casting lines.
Quantifizierte Ergebnisse nach 24 Monaten:
- Stickstoffgehalt des Öls: Reduced from 4.2 mg/m³ to <0.01 mg/m³, Erreichen der ISO 8573-1 Klasse 0 Zertifizierung
- Tundish nozzle clogging incidents: Vollständig eliminiert, improving casting yield by 1.2%
- Jährliche Wartungskosten: Reduced by 45% ($85,000 to $46,750) through elimination of oil-related repairs
- Energieverbrauch: Verbessert durch 6.8% versus the replaced unit, saving approximately $19,200/year
- Ungeplante Ausfallzeiten: Null Ereignisse in 24 Monaten ununterbrochenem Betrieb
“The LW-52/8 has transformed our nitrogen supply from a maintenance headache into a reliable utility. The elimination of oil contamination has improved our casting quality and reduced nozzle replacements by 80%. The payback period was under 20 months.” — Chief Engineer, Steel Mill Operations
Häufig gestellte Fragen & Auswahlhilfe
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Für einen umfassenden Überblick über unsere Industrieller Stickstoffkompressor Unser Portfolio umfasst unter anderem ölfreie Sauerstoffkompressoren, Wasserstoffkompressoren, Kohlendioxidkompressoren und kundenspezifische Spezialgaslösungen. Bitte kontaktieren Sie unser Anwendungstechnik-Team oder durchstöbern Sie unseren Online-Produktkatalog.
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