کمپرسور نیتروژن LW-10/20 – بوستر نیتروژن بدون روغن با فشار بالا برای کاربردهای صنعتی 2.00 مگاپاسکال

کمپرسور نیتروژن پیستونی دو مرحله‌ای و دو ردیفه بدون روغن LW-10/20 که برای ارائه دبی 10 متر مکعب در دقیقه با فشار تخلیه 2.00 مگاپاسکال طراحی شده است، به طور خاص برای تزریق نیتروژن با فشار بالا، پر کردن سیلندر گاز و کاربردهای فرآیند پتروشیمی دشوار ساخته شده است. بدون آلودگی روغن، ساختار مستحکم و بهینه شده برای کار مداوم در فشار بالا.

نمای کلی محصول

The LW-10/20 nitrogen compressor occupies a specialized position within our oil-free piston compressor portfolio, engineered for applications where elevated discharge pressure is the primary requirement rather than massive flow capacity. With a rated capacity of 10 m³/min و استثنایی 2.00 MPa discharge pressure, this unit bridges the gap between medium-pressure nitrogen distribution and high-pressure process applications that demand significantly elevated gas pressure.

What distinguishes the LW-10/20 from conventional alternatives is its مکانیزم فشرده‌سازی کاملاً بدون روغن 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 process gas supply, and electronics-grade nitrogen applications without requiring additional downstream purification equipment. The oil-free certification is particularly critical for high-pressure applications where oil contamination would be concentrated and more difficult to remove.

The compressor employs a دو مرحله ای، دو ردیفی (二列二级) configuration that is essential for managing the substantial pressure ratio required to achieve 2.00 MPa discharge pressure from typical inlet conditions. Each stage is independently cooled through a dedicated intercooler, ensuring gas temperatures remain within safe operating limits and preserving the dimensional stability of the PTFE sealing elements. The robust frame construction and precision-machined crankshaft assembly are rated for a minimum service life of ۱۲۰،۰۰۰ ساعت تحت پروتکل‌های استاندارد نگهداری.

Technical Specifications – LW-10/20

* 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. فناوری آب‌بندی PTFE بدون روغن در فشار بالا

The LW-10/20 utilizes a proprietary مجموعه رینگ پیستون و باند رادیال خود روان کننده manufactured from high-performance PTFE composites specifically formulated for high-pressure service. These rings are reinforced with glass fiber and bronze particulates to achieve a coefficient of friction below 0.06 without any external hydrocarbon lubrication. At 2.00 MPa discharge pressure, the risk of oil vapor carryover is magnified compared to lower-pressure applications, making the oil-free design not merely advantageous but absolutely essential. The PTFE composite formulation is rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity even under the thermal stress of high-pressure compression.

۲. فشرده‌سازی دو مرحله‌ای برای نسبت‌های فشار بسیار بالا

The معماری فشرده‌سازی دو مرحله‌ای of the LW-10/20 is thermodynamically essential for achieving the 2.00 MPa discharge pressure target from typical inlet pressures of 0.05–0.10 MPa. The overall pressure ratio of approximately 20:1 to 40:1 is split between a low-pressure cylinder and a high-pressure cylinder, with each stage operating at a manageable pressure ratio. A high-efficiency shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 165°C and preventing thermal degradation of the PTFE sealing elements. Without staged compression, the discharge temperature would exceed the safe operating limit of PTFE materials, making the two-stage design a fundamental requirement for this pressure level.

3. Robust Frame Construction for High-Pressure Loads

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 high-pressure cylinder features thicker wall castings and additional ribbing to withstand the mechanical stresses associated with 2.00 MPa peak pressures. 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 high-pressure compressors where the peak gas forces on the pistons are substantially higher than in low-pressure applications.

4. Flexible Voltage Configuration for Diverse Installations

The LW-10/20 is driven by a 110 kW induction motor available in 380V, 6kV, or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The standard 380V configuration is suitable for facilities with existing low-voltage distribution infrastructure, while the 6kV and 10kV options allow direct integration into medium-voltage industrial networks without step-down transformers. This electrical flexibility makes the LW-10/20 adaptable to a wide range of installation environments, from small industrial facilities to large integrated plants with medium-voltage bus systems.

سناریوهای کاربردی

ایستگاه‌های پر کردن سیلندر نیتروژن با فشار بالا

The LW-10/20 is ideally suited for عملیات پر کردن سیلندر نیتروژن where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa filling pressure. While the compressor’s 2.00 MPa discharge pressure does not reach cylinder filling pressure directly, it serves as an efficient intermediate booster that significantly reduces the compression ratio required of downstream high-pressure filling compressors. This staged approach improves overall system efficiency and reduces wear on the expensive high-pressure filling equipment. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users, compromising their processes.

نیتروژن فرآیند فشار بالای پتروشیمی

In petrochemical and refinery operations, the LW-10/20 provides high-pressure nitrogen for reactor catalyst preservation, emergency nitrogen injection into high-pressure vessels, and pipeline pressure testing. The 2.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 1.6 MPa, maintaining positive inert gas blankets during startup, shutdown, and upset conditions. The LW-10/20 high-pressure nitrogen booster is also used for hydrostatic testing of process piping and pressure vessels, where nitrogen is used as a test medium to avoid water contamination in systems that must remain dry.

Pharmaceutical Process Gas Supply

Pharmaceutical manufacturing facilities require high-purity nitrogen at elevated pressure for sterile filtration, lyophilization (freeze-drying), and aseptic filling operations. The LW-10/20’s oil-free certification ensures compliance with FDA 21 CFR 211.72 (equipment construction requirements) and EU GMP Annex 1 (manufacture of sterile medicinal products). The 2.00 MPa discharge pressure provides adequate head to drive nitrogen through sterile filtration systems, spray dryers, and fluid bed processors that operate at elevated pressures. The 10 m³/min capacity can simultaneously supply multiple pharmaceutical process units within a single manufacturing facility.

Electronics High-Pressure Nitrogen Purge

Semiconductor fabrication facilities and electronics assembly plants require high-pressure nitrogen for wafer handling system purge, chemical vapor deposition (CVD) chamber cleaning, and high-pressure drying of precision components. The LW-10/20’s 2.00 MPa discharge pressure is sufficient for driving high-velocity nitrogen jets used in precision cleaning applications and for maintaining positive pressure in wafer transport systems. The oil-free design is absolutely critical in semiconductor applications where even sub-ppm oil contamination can cause catastrophic defects in integrated circuit manufacturing.

مواد و ساخت و ساز

The LW-10/20 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 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2, and each completed pressure vessel is subjected to a hydrostatic pressure test at 1.5 times the maximum allowable working pressure (MAWP) for a minimum hold period of 30 minutes. High-pressure piping systems are fabricated from seamless SS316 with ANSI Class 600 flanged connections to ensure leak-tight integrity at 2.00 MPa operating pressure.

دستورالعمل‌های نصب و نگهداری

الزامات فونداسیون و سازه

The LW-10/20 has a dry weight of 3.00 tonnes and a center of gravity approximately 800 mm above the baseplate. Due to the two-row opposed-cylinder design, unbalanced forces are minimal despite the high-pressure operation, permitting installation on a بلوک اینرسی بتن مسلح ۵ تا ۶ تنی. The block should be mounted on elastomeric vibration isolators (natural frequency 7–10 Hz). Minimum clearance requirements: 1.2 m on the non-drive side for valve access, 1.0 m on the drive side for motor maintenance, and 1.5 m overhead for crane access during major overhauls. Special attention must be paid to the high-pressure discharge piping, which must be properly supported and anchored to prevent vibration-induced fatigue.

طراحی سیستم آب خنک کننده

تقاضای آب خنک کننده تقریباً است 18 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches. Given the high pressure ratio, the intercooler is particularly critical for thermal management and must receive adequate cooling water flow at all times. 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 is recommended for sites with marginal water quality.

برنامه نگهداری پیشگیرانه

The oil-free design of the LW-10/20 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 حلقه‌های پیستون و نوارهای پیستونی PTFE, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. The high-pressure valve plates may require more frequent inspection than low-pressure equivalents due to the increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

گواهینامه‌های انطباق و ایمنی

The LW-10/20 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

تحلیل عملکرد و کارایی

The LW-10/20 achieves a specific power consumption of approximately 11.00 kW per m³/min of nitrogen delivered at 2.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of high-pressure compression, where the work required increases substantially with pressure ratio. Within the high-pressure oil-free piston compressor segment (discharge pressure >1.50 MPa), this efficiency is competitive and often superior to diaphragm compressors, which are the primary alternative for oil-free high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar high-pressure applications typically consume 11.5–13.0 kW/m³/min, while diaphragm compressors may exceed 15 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the LW-10/20’s efficiency advantage versus less efficient alternatives yields approximately 40,000–80,000 kWh of annual energy savings. At $0.08/kWh, this represents $3,200–$6,400 in direct electricity cost reduction per year. However, the primary economic justification for the LW-10/20 is typically the حذف مواد مصرفی مرتبط با نفت و اجتناب از تجهیزات پایین‌دستی حذف نفت که با جایگزین‌های روغن‌کاری‌شده اجباری خواهد بود. هزینه کل مالکیت برای فشرده سازی نیتروژن با فشار بالا در مقایسه با سیستم‌های روغن‌کاری‌شده با تصفیه کامل پایین‌دستی، در طول یک عمر عملیاتی 10 ساله، میزان مصرف سوخت در حالت بدون روغن حدود 25 تا 35 درصد کاهش می‌یابد.

The absence of oil in the compression path is particularly valuable at high pressure because oil contamination becomes more concentrated and more difficult to remove as pressure increases. At 2.00 MPa, the partial pressure of oil vapor is significantly higher than at 0.30 MPa, making downstream oil-filtration systems less effective and more expensive. The LW-10/20’s native oil-free design eliminates this challenge entirely.

قابلیت‌های سفارشی‌سازی و نصب‌شده

We offer comprehensive customization options to adapt the LW-10/20 to specific site conditions, integration requirements, and end-user specifications:

• بسته‌های آماده تحویل با نصب روی شاسی: 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. Reduces field installation to electrical connection and cooling water hookup only.
• پیکربندی‌های منطقه خطرناک: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks can be incorporated into the control system.
• 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 DCS/SCADA integration. High-pressure safety interlocks including automatic unload on overpressure and emergency isolation valves.
• حفاظت از محیط زیست: C5-M marine-grade coatings for coastal installations; tropicalized electrical components for 55°C ambient; IP54-rated acoustic enclosures reducing noise from 85 dB(A) to 72 dB(A) at 1 meter.
• برچسب نصب شده و خصوصی: رنگ‌های سفارشی، پلاک‌های برند و مستندات محلی برای توزیع‌کنندگان تجهیزات گاز و یکپارچه‌سازان سیستم.

پیکربندی‌های سفارشی از [نام شرکت/شرکت/...] در دسترس هستند. حداقل سفارش ۱ واحد. Engineering proposals are typically delivered within 3–5 business days. Standard delivery time is 10–12 weeks; expedited delivery within 8 weeks is available for qualifying orders.

Case Study: Pharmaceutical Nitrogen Cylinder Filling Station

مشتری: A pharmaceutical gas supplier in India serving hospitals and pharmaceutical manufacturers

چالش: The client was operating an oil-lubricated high-pressure compressor for filling medical-grade nitrogen cylinders. Oil contamination levels in the filled cylinders reached 1.5 mg/m³, exceeding the 0.1 mg/m³ specification required by pharmaceutical customers and hospital gas standards. The oil was also degrading the activated carbon purification beds in the cylinder filling manifold, requiring replacement every 6 months. Customer complaints and regulatory scrutiny were increasing.

راه حل: ما عرضه کردیم LW-10/20 oil-free nitrogen compressor as the primary booster, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel. The 2.00 MPa discharge pressure fed a downstream high-pressure filling compressor, reducing the overall compression ratio required of the filling stage and improving system efficiency. The oil-free design eliminated the need for activated carbon purification beds entirely.

نتایج کمی پس از ۱۸ ماه:

• Nitrogen oil content in filled cylinders: Reduced from 1.5 mg/m³ to <0.01 mg/m³، دستیابی به استاندارد ISO 8573-1 کلاس 0
• جایگزینی بستر کربن فعال: کاملاً حذف شد, saving $8,000/year in consumables
• شکایات مشتریان: صفر since commissioning, with three new pharmaceutical contracts won
• تعمیر و نگهداری کمپرسور پرکن: Reduced by 30% به دلیل نسبت فشار ورودی کمتر
• دوره بازگشت سرمایه: ۲.۱ سال بر اساس صرفه‌جویی در هزینه‌ها و درآمد حاصل از قراردادهای جدید

“The LW-10/20 has been a game-changer for our medical gas business. We now guarantee ISO 8573-1 Class 0 nitrogen to all our customers, and we’ve won contracts that we couldn’t compete for before. The oil-free design has eliminated our biggest quality headache.” — Managing Director, Pharmaceutical Gas Supplier

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.

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ایمیل: [email protected] | پاسخ ظرف ۲۴ ساعت