کمپرسور نیتروژن LW-25/10 – بوستر نیتروژن بدون روغن با فشار بالا برای کاربردهای صنعتی 1.00 مگاپاسکال

کمپرسور نیتروژن پیستونی دو مرحله‌ای و دو ردیفه بدون روغن LW-25/10 که برای ارائه دبی ۲۵ متر مکعب در دقیقه با فشار تخلیه ۱ مگاپاسکال طراحی شده است، به طور خاص برای تزریق نیتروژن با فشار بالا، تقویت خطوط لوله و کاربردهای فرآیند پتروشیمی دشوار ساخته شده است. بدون آلودگی روان‌کننده، دارای رتبه‌بندی کار مداوم و بهینه شده برای عملیات صنعتی ۲۴ ساعته و ۷ روز هفته در فشار بالا.

نمای کلی محصول

The LW-25/10 nitrogen compressor represents a specialized high-pressure solution within our oil-free piston compressor portfolio, engineered for applications where both substantial flow and elevated discharge pressure are non-negotiable requirements. With a rated capacity of 25 m³/min و استثنایی 1.00 MPa discharge pressure, this unit occupies a unique position at the intersection of high-flow and high-pressure nitrogen compression.

What distinguishes the LW-25/10 from conventional high-pressure alternatives is its fully oil-free compression mechanism. The piston rings and rider bands are fabricated from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This intrinsic oil-free characteristic delivers گواهینامه ISO 8573-1 کلاس 0 natively, making the unit immediately suitable for the most demanding applications including food-grade nitrogen, pharmaceutical process gas, semiconductor fabrication, and petrochemical reactor inerting without additional downstream purification.

The compressor employs a دو مرحله ای، دو ردیفی (二列二级) configuration that carefully manages the high pressure ratio required for 1.00 MPa discharge. By dividing the compression work across two cylinders with an optimized inter-stage pressure, the LW-25/10 maintains thermal stability and preserves the integrity of the PTFE sealing elements even under sustained maximum-load operation. The robust cast-iron frame and precision-balanced forged steel crankshaft are rated for a minimum service life of ۱۲۰،۰۰۰ ساعت تحت پروتکل‌های استاندارد نگهداری.

Technical Specifications – LW-25/10

* تمام مشخصات در شرایط مرجع استاندارد (ISO 1217، پیوست C) رتبه‌بندی شده‌اند. عملکرد واقعی ممکن است بر اساس ارتفاع محل، دمای محیط و شرایط ورودی متفاوت باشد.

ویژگی‌های کلیدی و مزایای مهندسی

1. High-Temperature Oil-Free PTFE Sealing Technology

The LW-25/10 utilizes a proprietary مجموعه رینگ پیستون و باند رادیال خود روان کننده manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates, specifically formulated for high-pressure service. This material achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover into the nitrogen product stream. The rings are engineered for the elevated discharge temperatures associated with 1.00 MPa operation, maintaining dimensional stability and sealing integrity up to 190°C. For operators in regulated industries, this delivers انطباق با استاندارد ISO 8573-1 کلاس 0 without the capital cost, maintenance burden, or energy penalty of downstream oil-filtration systems.

2. Optimized Two-Stage High-Pressure Thermodynamic Design

The معماری فشرده‌سازی دو مرحله‌ای of the LW-25/10 is thermodynamically optimized for the demanding 1.00 MPa discharge pressure target. By carefully dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder with an optimized inter-stage pressure, the compressor achieves a significantly lower mean effective temperature per stage compared to single-stage designs. A high-efficiency shell-and-tube intercooler between stages removes the heat of compression, maintaining discharge temperatures below 160°C even at maximum continuous load. This advanced thermal management is essential for preserving PTFE ring integrity at high pressure ratios and extends valve plate service life by approximately 45% versus single-stage alternatives.

3. Reinforced Cast-Iron Frame with Force Balance

قاب اصلی از ریخته گری ساخته شده است چدن خاکستری GG25 (equivalent to ASTM A48 Class 30B) with reinforced wall sections and integral cooling water passages. The آرایش دو ردیفه سیلندرهای مخالف provides natural first-order force cancellation, reducing unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs. This mechanical advantage is particularly valuable for the LW-25/10 given its high-pressure operation, where reciprocating forces are substantially higher than low-pressure equivalents. The reduced vibration transmission permits installation on a lighter reinforced concrete inertia block (minimum 8 tonnes versus 12+ tonnes for single-row high-pressure equivalents), reducing civil engineering costs.

4. Flexible Voltage Configuration for Industrial Integration

The LW-25/10 is driven by a 200 kW induction motor available in 380V, 6kV, or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The flexible voltage options allow direct integration into diverse industrial electrical infrastructures: the 380V configuration suits facilities with existing low-voltage distribution, while the 6kV and 10kV options eliminate the need for step-down transformers in large industrial plants with medium-voltage bus systems. This electrical versatility reduces infrastructure costs and improves overall energy efficiency by minimizing transformation losses.

سناریوهای کاربردی

High-Pressure Nitrogen Injection for Petrochemical Reactors

In petrochemical and refining operations, the LW-25/10 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, emergency nitrogen injection, and process vessel purging. The 1.00 MPa discharge pressure is sufficient to overcome the operating pressures of typical fixed-bed reactors, fluid catalytic cracking units, and hydrocracker systems, allowing direct nitrogen injection without intermediate boosting. 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 to prevent catalyst poisoning or product contamination.

ایستگاه‌های تقویت فشار بالای نیتروژن VPSA

For VPSA nitrogen generators producing high-purity nitrogen at near-atmospheric pressure, the LW-25/10 high-pressure nitrogen booster compresses the low-pressure product to 1.00 MPa for demanding distribution applications. The elevated discharge pressure is particularly valuable for VPSA installations serving high-pressure process consumers, long-distance pipeline networks with significant friction losses, or facilities requiring nitrogen at pressure for direct injection into process vessels. The oil-free compression path is absolutely essential because hydrocarbon contamination would permanently poison the carbon molecular sieve adsorbent, degrading separation efficiency and requiring costly adsorbent replacement.

Pipeline Nitrogen Boosting & Pressure Maintenance

Industrial gas distribution networks spanning multiple kilometers require nitrogen at elevated pressure to overcome pipeline friction losses and maintain adequate flow at remote consumers. The LW-25/10’s 1.00 MPa discharge pressure provides sufficient head for distribution over distances up to 5 km through DN200 pipelines, making it suitable for centralized nitrogen supply to large industrial complexes, chemical parks, and integrated manufacturing facilities. The 25 m³/min capacity supports multiple high-pressure consumers simultaneously, including reactor inerting systems, tank blanketing stations, and emergency nitrogen injection points.

High-Pressure Food Packaging & Modified Atmosphere Systems

Large-scale food packaging facilities with high-speed MAP (Modified Atmosphere Packaging) lines require nitrogen at elevated pressure to achieve rapid gas displacement in packaging chambers. The LW-25/10’s 1.00 MPa discharge pressure enables fast-fill nitrogen injection, reducing cycle times and increasing packaging line throughput. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-grade nitrogen. The absence of oil contamination eliminates risks of off-flavors, rancidity, or product discoloration that can occur with lubricated compressors in food-contact applications.

مواد و ساخت و ساز

The LW-25/10 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal resistance, and extended operational life:

تمام اجزای تحمل فشار مطابق با الزامات طراحی و ساخته می‌شوند. بخش 1 ASME BPVC بخش VIII یا استانداردهای GB 150 چین. هر اتصال جوش طبق ماده 2 بخش V استاندارد ASME، تحت بازرسی رادیوگرافی (RT) 100% قرار می‌گیرد و هر مخزن تحت فشار تکمیل‌شده تحت آزمایش فشار هیدرواستاتیک با 1.5 برابر حداکثر فشار کاری مجاز (MAWP) به مدت حداقل 30 دقیقه قرار می‌گیرد.

دستورالعمل‌های نصب و نگهداری

الزامات فونداسیون و سازه

The LW-25/10 has a dry weight of 4.50 tonnes and a center of gravity approximately 950 mm above the baseplate. Due to the two-row opposed-cylinder design, unbalanced forces are significantly reduced despite the high-pressure operation, permitting installation on a reinforced concrete inertia block of 8–10 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz) to prevent vibration transmission. 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.

طراحی سیستم آب خنک کننده

تقاضای آب خنک کننده تقریباً است 28 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), 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 in the high-pressure cooling circuits.

برنامه نگهداری پیشگیرانه

The oil-free design of the LW-25/10 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 حلقه‌های پیستون و نوارهای پیستونی PTFEکه معمولاً در شرایط نیتروژن پاک به ۴۰۰۰ تا ۶۰۰۰ ساعت عمر مفید می‌رسند. این ساده‌سازی تعمیر و نگهداری به کاهش هزینه‌های نیروی کار، کاهش موجودی قطعات یدکی و افزایش در دسترس بودن تجهیزات منجر می‌شود.

گواهینامه‌های انطباق و ایمنی

The LW-25/10 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

تحلیل عملکرد و کارایی

The LW-25/10 achieves a specific power consumption of approximately 8.00 kW per m³/min of nitrogen delivered at 1.00 MPa discharge pressure. This efficiency metric is respectable for an oil-free piston compressor operating at a high pressure ratio, reflecting the thermodynamic challenges of compressing nitrogen to 1.00 MPa. For comparison, oil-lubricated screw compressors in similar high-pressure applications typically consume 8.5–9.5 kW/m³/min, while diaphragm compressors (often selected for oil-free high-pressure service) can exceed 12 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the LW-25/10’s efficiency advantage generates approximately 40,000–100,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $3,200–$8,000 in direct operating cost reduction per year. However, the primary economic driver for LW-25/10 selection is typically the elimination of oil-related consumables and downstream purification equipment rather than marginal energy savings.

The total cost of ownership for high-pressure nitrogen compression is significantly reduced by the absence of oil in the compression path. A typical oil-lubricated compressor of this pressure rating requires coalescing filters, activated carbon adsorbers, oil monitoring instrumentation, and periodic oil changes that collectively add $8,000–$15,000 in annual operating costs. The LW-25/10’s oil-free design eliminates these expenses entirely, while also removing the 3–5% energy penalty associated with downstream oil-removal equipment.

قابلیت‌های سفارشی‌سازی و نصب‌شده

We provide comprehensive customization options to adapt the LW-25/10 to specific site conditions, integration requirements, and end-user specifications:

• بسته‌های آماده تحویل با نصب روی شاسی: The compressor, motor, intercooler, aftercooler, high-pressure instrumentation, and control panel are pre-assembled on a structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces field commissioning time by approximately 60% and minimizes startup risks.
• پیکربندی‌های منطقه خطرناک: محفظه‌های موتور و برق مطابق با ATEX Zone 2 و IECEx برای نصب در تأسیسات پتروشیمی که ممکن است گاهی اوقات در آنها جوهای انفجاری وجود داشته باشد، در دسترس هستند. می‌توان سیستم‌های تشخیص گاز یکپارچه و قفل‌های تهویه خودکار را در سیستم کنترل گنجاند.
• کنترل فرآیند پیشرفته: 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.
• High-Pressure Package Options: Integrated high-pressure receiver vessels, pressure regulation skids, and nitrogen distribution manifolds can be supplied as part of a complete system package. All high-pressure components are designed and tested to ASME BPVC standards.
• برنامه‌های OEM و برچسب خصوصی: رنگ‌های سفارشی، پلاک‌های برند و بسته‌های مستندات محلی برای توزیع‌کنندگان تجهیزات گاز و یکپارچه‌سازان سیستم در دسترس هستند. دفترچه‌های راهنمای فنی، لیست قطعات یدکی و رویه‌های نگهداری می‌توانند به چندین زبان ارائه شوند.

پیکربندی‌های سفارشی از [نام شرکت/شرکت/...] در دسترس هستند. حداقل سفارش ۱ واحدبررسی مهندسی و تهیه پیشنهاد معمولاً ۵ تا ۷ روز کاری زمان می‌برد. زمان تحویل استاندارد ۱۲ تا ۱۴ هفته است؛ سفارش‌های تکراری ۸ تا ۱۰ هفته پس از تأیید سفارش تحویل داده می‌شوند.

Case Study: Petrochemical Reactor Nitrogen Injection System

مشتری: A major petrochemical complex in the Middle East operating polyethylene and polypropylene production units

چالش: The client’s existing oil-lubricated nitrogen compressor (American brand, 12 years in service) was experiencing progressive oil carryover into the nitrogen injection system used for reactor inerting and catalyst bed preservation. Oil contamination levels reached 3.5 mg/m³, exceeding the 0.1 mg/m³ limit specified by the catalyst supplier. The oil was deactivating the Ziegler-Natta catalyst, reducing polymer yield by 2.8% and requiring premature catalyst replacement at a cost of $180,000 per campaign. Additionally, the compressor’s 0.70 MPa discharge pressure was insufficient for new high-pressure reactor designs requiring 0.95 MPa nitrogen.

راه حل: ما عرضه کردیم LW-25/10 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with integrated intercooler, aftercooler, high-pressure receiver vessel, and a Siemens S7-1200 PLC control panel with DCS integration. The 1.00 MPa discharge pressure met the new reactor requirements with margin, while the oil-free design eliminated catalyst contamination. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from multiple reactor units.

Quantified Results After 18 Months:

• میزان نیتروژن روغن: Reduced from 3.5 mg/m³ to <0.01 mg/m³، اخذ گواهینامه ISO 8573-1 کلاس 0
• Catalyst deactivation incidents: کاملاً حذف شد, restoring polymer yield to design specifications
• Catalyst replacement frequency: Extended from 12 months to 24 months, saving $180,000 per cycle
• هزینه نگهداری سالانه: کاهش یافته توسط 48% through elimination of oil-related repairs and separator overhauls
• خرابی‌های برنامه‌ریزی نشده: صفر رویداد in 18 months of continuous operation

“The LW-25/10 solved our catalyst contamination problem permanently. The 1.00 MPa pressure gives us the margin we need for new reactor designs, and the oil-free design has eliminated our most persistent operational headache. The payback was under 14 months.” — Process Engineering Manager, Petrochemical Complex

سوالات متداول و راهنمای انتخاب

محصولات و راهکارهای مرتبط

برای یک مرور کلی جامع از ما کمپرسور نیتروژن صنعتی برای اطلاع از نمونه کارهای ما، شامل کمپرسورهای اکسیژن بدون روغن، کمپرسورهای هیدروژن، کمپرسورهای دی اکسید کربن و راهکارهای تخصصی گازسوز سفارشی، لطفاً با تیم مهندسی کاربردی ما تماس بگیرید یا کاتالوگ محصولات آنلاین ما را مرور کنید.

Ready to Upgrade Your High-Pressure Nitrogen System?

مهندسان ما آماده‌اند تا نیازهای جریان نیتروژن، شرایط مکش، اهداف فشار تخلیه و محدودیت‌های یکپارچه‌سازی شما را ارزیابی کنند. ما ظرف ۴۸ ساعت پس از دریافت درخواست شما، پیشنهادهای فنی رایگان، نقشه‌های چیدمان فونداسیون، نمودارهای لوله‌کشی و ابزار دقیق (P&ID) و تجزیه و تحلیل دقیق هزینه کل مالکیت (TCO) را ارائه می‌دهیم.

ایمیل: [email protected] | پاسخ ظرف ۲۴ ساعت