کمپرسور نیتروژن DW-120/8 – تقویت‌کننده نیتروژن بدون روغن با ظرفیت فوق‌العاده بالا برای زیرساخت‌های گاز صنعتی مورد نیاز

Engineered to deliver an exceptional 120 m³/min at 0.80 MPa discharge pressure, the DW-120/8 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for mega-scale cryogenic air separation, high-pressure VPSA booster stations, and extensive petrochemical pipeline distribution networks. Zero lubricant contamination, continuous-duty rated, and optimized for 24/7 operation at the highest industrial throughput levels.

نمای کلی محصول

The DW-120/8 nitrogen compressor represents the pinnacle of our oil-free piston compressor engineering, occupying the ultra-high-capacity segment of our industrial nitrogen booster portfolio. With an extraordinary rated capacity of 120 m³/min and a robust فشار تخلیه 0.80 مگاپاسکالاین واحد به گونه‌ای طراحی شده است که بتواند سخت‌ترین نیازهای توزیع نیتروژن را در زیرساخت‌های گاز صنعتی در مقیاس بزرگ در سراسر جهان برآورده کند.

What distinguishes the DW-120/8 from all conventional alternatives is its مسیر فشرده‌سازی کاملاً بدون روغن utilizing self-lubricating PTFE composite piston rings and rider bands. These advanced sealing elements operate without any hydrocarbon lubricants, ensuring the nitrogen product stream remains entirely free of oil contamination. This intrinsic oil-free characteristic delivers گواهینامه ISO 8573-1 کلاس 0 natively, eliminating the capital expenditure, maintenance burden, and energy penalty of downstream oil-removal filtration systems. For operators in food processing, pharmaceutical manufacturing, semiconductor fabrication, and petrochemical processing, this native purity is non-negotiable.

معماری کمپرسور از یک دو مرحله ای، دو ردیفی (二列二级) configuration that optimally distributes the substantial pressure ratio across two compression cylinders. This staged approach is essential for managing the thermal loads associated with compressing 120 m³/min to 0.80 MPa while preserving the integrity of the PTFE sealing elements. Each stage features a high-efficiency intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-capacity operation. The massive cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of ۱۲۰،۰۰۰ ساعت تحت پروتکل‌های دقیق نگهداری.

Technical Specifications – DW-120/8

* 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

۱. فشرده‌سازی بدون روغن با ظرفیت فوق‌العاده بالا

The DW-120/8 employs a proprietary سیستم رینگ پیستون و باند رادیال خود روان کننده manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. This advanced 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. At 120 m³/min capacity, even trace oil contamination would represent a massive cumulative contamination burden—making the DW-120/8’s native oil-free design absolutely critical. For industrial gas operators, this delivers انطباق با استاندارد ISO 8573-1 کلاس 0 without the capital cost, maintenance burden, or energy penalty of downstream oil-filtration equipment that would be required for a lubricated compressor of this scale.

۲. بهینه‌سازی ترمودینامیکی دو مرحله‌ای برای فشار بالا

The معماری فشرده‌سازی دو مرحله‌ای of the DW-120/8 is thermodynamically optimized for the demanding 0.80 MPa discharge pressure target while managing the enormous flow volume of 120 m³/min. 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. A dedicated high-capacity shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 155°C even at maximum continuous load. This thermal management is essential for preserving PTFE ring integrity at this scale and extends valve plate service life by approximately 40% compared to single-stage designs operating at equivalent pressure ratios.

۳. قاب چدنی عظیم با تعادل نیروی برتر

قاب اصلی از ریخته گری ساخته شده است چدن خاکستری GG25 (معادل ASTM A48 کلاس 30B) با مجاری آب خنک‌کننده یکپارچه. آرایش دو ردیفه سیلندرهای مخالف provides natural first-order force cancellation, reducing the unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs. Despite the massive 15.00-tonne weight, this mechanical advantage permits installation on a بلوک اینرسی بتن مسلح ۲۵ تا ۳۰ تنی—proportionally lighter than the foundation requirements for single-row compressors of equivalent capacity. This foundation efficiency is particularly valuable for retrofit installations in existing compressor houses where civil modifications are costly and disruptive.

۴. درایو موتور ولتاژ متوسط ​​با توان بالا

The DW-120/8 is driven by a موتور القایی ولتاژ متوسط ​​۷۱۰ کیلووات available in either 6kV or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. At this power level, medium-voltage drive is essential—a 380V motor would require impractical cable sizes and switchgear ratings. The medium-voltage configuration integrates directly into industrial medium-voltage distribution networks, minimizing I²R losses in power cabling and improving overall energy efficiency. For large industrial facilities with 6kV or 10kV bus systems, the DW-120/8 offers seamless electrical compatibility without additional infrastructure investment.

سناریوهای کاربردی

کارخانه‌های جداسازی هوای کرایوژنیک در مقیاس بزرگ

In mega-scale cryogenic ASU facilities producing 5,000–15,000 Nm³/h of gaseous nitrogen, the DW-120/8 serves as the تقویت کننده نیتروژن اولیه با ظرفیت بالا between the cold box and the extensive distribution network. Its 120 m³/min capacity matches the output of the largest standalone ASUs, while the 0.80 MPa discharge pressure provides sufficient head for long-distance pipeline distribution to multiple downstream consumers across an integrated industrial complex. The oil-free design is critical in these applications because any oil contamination would compromise nitrogen purity across the entire distribution network, affecting sensitive processes in semiconductor, pharmaceutical, and food manufacturing facilities served by the same header.

Large-Scale VPSA Nitrogen Booster Stations

For large VPSA nitrogen generator installations producing 99.5–99.9% purity nitrogen at near-atmospheric pressure, the DW-120/8 nitrogen booster compresses the low-pressure product to 0.80 MPa for high-pressure distribution across extensive industrial sites. The 120 m³/min capacity can serve multiple large VPSA generators operating in parallel, creating a centralized nitrogen supply hub. 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 across all generators and necessitating costly adsorbent replacement on a massive scale.

Integrated Petrochemical Complex Nitrogen Distribution

In integrated petrochemical complexes, the DW-120/8 provides high-pressure nitrogen for بی‌اثرسازی راکتور، حفظ کاتالیزور، پاکسازی خط لوله، تزریق اضطراری نیتروژن و پوشش‌دهی مخازن across multiple process units. The 0.80 MPa discharge pressure is sufficient to overcome the pressure ratings of typical process vessels, distillation columns, and reactor systems, allowing direct nitrogen injection without intermediate boosting. The 120 m³/min capacity can simultaneously serve an entire complex through a centralized high-pressure nitrogen header, eliminating the need for multiple smaller compressors and reducing overall maintenance complexity. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams.

LNG Regasification Terminal Inerting

LNG regasification terminals require massive volumes of nitrogen for storage tank inerting, pipeline purging, and emergency gas displacement during maintenance and upset conditions. The DW-120/8’s 120 m³/min capacity can rapidly inert large LNG storage tanks and maintain positive nitrogen pressure during product withdrawal cycles. The 0.80 MPa discharge pressure provides adequate head for distribution across the terminal’s extensive piping network. The oil-free design prevents oil contamination of LNG product, which would create off-specification gas and compromise downstream combustion equipment.

مواد و ساخت و ساز

The DW-120/8 is constructed from premium materials selected for nitrogen compatibility, high-pressure service, and extended operational life at massive scale:

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 DW-120/8 has a dry weight of 15.00 tonnes and a center of gravity approximately 1,000 mm above the baseplate. Despite the massive scale, the two-row opposed-cylinder design minimizes unbalanced forces, permitting installation on a بلوک اینرسی بتن مسلح ۲۵ تا ۳۰ تنی. The block should be mounted on heavy-duty elastomeric vibration isolators (natural frequency 5–7 Hz) to prevent vibration transmission to adjacent structures and sensitive instrumentation. Minimum clearance requirements: 2.0 m on the non-drive side for valve access, 1.5 m on the drive side for motor maintenance, and 2.5 m overhead for crane access during major overhauls. The foundation must be designed to support the full static weight plus a dynamic factor of 1.5.

طراحی سیستم آب خنک کننده

تقاضای آب خنک کننده تقریباً است ۱۲۰ متر مکعب در ساعت 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. 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 dedicated closed-loop cooling tower with side-stream filtration, water softening, and chemical treatment is mandatory to prevent scale formation and corrosion in the high-capacity coolers.

برنامه نگهداری پیشگیرانه

The oil-free design of the DW-120/8 dramatically reduces maintenance complexity compared to lubricated alternatives of equivalent capacity. 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 PTFE, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions. At this scale, the elimination of oil-related maintenance represents annual savings of $15,000–$25,000 in labor and consumables alone.

گواهینامه‌های انطباق و ایمنی

The DW-120/8 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

تحلیل عملکرد و کارایی

The DW-120/8 achieves a specific power consumption of approximately 5.92 kW per m³/min of nitrogen delivered at 0.80 MPa discharge pressure. This efficiency metric is exceptional for an ultra-high-capacity oil-free piston compressor operating at an elevated pressure ratio, positioning the unit in the top tier of the 100+ m³/min capacity class. For comparison, oil-lubricated screw compressors in similar high-pressure, high-flow applications typically consume 6.2–7.0 kW/m³/min, while legacy piston designs may exceed 7.5 kW/m³/min at equivalent discharge pressures.

Over a standard 8,000-hour annual operating schedule, the DW-120/8’s efficiency advantage generates approximately 240,000–480,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $19,200–$38,400 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 هزینه کل مالکیت برای فشرده سازی نیتروژن در طول یک دوره عملیاتی 10 ساله، به میزان تخمینی 22-32% کاهش می‌یابد.

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 would require massive coalescing filter systems, activated carbon adsorber beds, and continuous oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output—equivalent to 21–35 kW of parasitic load. The DW-120/8’s oil-free design removes this parasitic load entirely, further improving effective system efficiency and reducing the electrical infrastructure requirements.

قابلیت‌های سفارشی‌سازی و نصب‌شده

We offer comprehensive customization options to adapt the DW-120/8 to specific site conditions, integration requirements, and end-user specifications:

• بسته‌های آماده تحویل با نصب روی شاسی: The compressor, motor, intercooler, aftercooler, instrumentation, and control panel are pre-assembled on a heavy structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces field installation time by approximately 60% and minimizes commissioning 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 S7-1500 or Allen-Bradley ControlLogix PLC with 15-inch HMI touchscreen, remote monitoring via Modbus TCP/IP or OPC-UA, and seamless integration with plant DCS/SCADA systems. Automatic load/unload control, variable frequency drive (VFD) compatibility, and predictive maintenance algorithms optimize part-load efficiency and reduce mechanical wear.
• سیستم‌های حفاظت از محیط زیست: 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 that reduce noise emission from 88 dB(A) to 74 dB(A) at 1 meter, suitable for installations near administrative buildings or residential areas.
• 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 واحد. Engineering review and proposal generation typically require 7–10 business days due to the complexity of ultra-high-capacity systems. Standard delivery time is 14–16 weeks; repeat orders are delivered in 10–12 weeks from order confirmation.

Case Study: Integrated Petrochemical Complex Nitrogen Hub

مشتری: A major integrated petrochemical complex in the Middle East with ethylene crackers, polyethylene plants, and aromatics units

چالش: The complex was operating three aging oil-lubricated nitrogen compressors (combined capacity 100 m³/min at 0.60 MPa) that were experiencing frequent oil carryover into the nitrogen distribution network. Oil contamination was fouling catalyst beds in the ethylene crackers, causing unplanned shutdowns costing $500,000 per event. The 0.60 MPa pressure was also insufficient for new high-pressure reactor inerting requirements. Maintenance costs across the three compressors had escalated to $220,000/year, and spare parts availability was becoming problematic due to the age of the equipment.

راه حل: ما یک تک‌نسخه عرضه کردیم DW-120/8 oil-free nitrogen compressor to replace all three aging units, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1500 PLC control panel with full SCADA integration. The 0.80 MPa discharge pressure met all new high-pressure inerting requirements, while the 120 m³/min capacity provided a 20% margin above peak demand. A 10 m³ surge vessel was installed upstream to buffer demand fluctuations across the complex. The oil-free design eliminated catalyst bed fouling entirely.

نتایج کمی پس از 30 ماه:

• میزان نیتروژن روغن: از ۵.۸ میلی‌گرم بر متر مکعب به کمتر از ۰.۰۱ میلی‌گرم بر متر مکعب کاهش یافت، اخذ گواهینامه ISO 8573-1 کلاس 0
• Catalyst bed fouling incidents: کاملاً حذف شد, saving $500,000 per avoided shutdown
• هزینه نگهداری سالانه: کاهش یافته توسط 48% ($220,000 to $114,400) through elimination of oil-related repairs across three units
• مصرف انرژی: بهبود یافته توسط 8.2% versus the three replaced units, saving approximately $42,000/year
• کاهش ردپا: Replaced three compressors with one, freeing 40 m² of compressor house space
• خرابی‌های برنامه‌ریزی نشده: صفر رویداد در 30 ماه کارکرد مداوم

“The DW-120/8 has been a game-changer for our nitrogen supply. Eliminating oil contamination saved us from two catalyst bed replacements that would have cost $2.5 million each. The single-unit simplicity has reduced our maintenance team workload by 60%, and the energy savings are a welcome bonus.” - مدیر ارشد عملیات، مجتمع پتروشیمی

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.

آماده‌اید تا زیرساخت نیتروژن در مقیاس بزرگ خود را متحول کنید؟

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