کمپرسور نیتروژن LW-13/30 – بوستر N2 بدون روغن با ظرفیت متوسط ​​برای کاربردهای فرآیندی با فشار بالا 3.00 مگاپاسکال

کمپرسور نیتروژن پیستونی دو مرحله‌ای سه ردیفه بدون روغن LW-13/30 که برای ارائه دبی ۱۳ متر مکعب در دقیقه با فشار تخلیه ۳ مگاپاسکال طراحی شده است، برای تزریق نیتروژن با فشار بالا، تقویت‌کننده مایع‌سازی گاز و کاربردهای دشوار فرآیندهای پتروشیمی طراحی شده است. آلودگی روغن صفر، دارای رتبه‌بندی کار مداوم و ساخته شده برای قابلیت اطمینان صنعتی ۲۴ ساعته و ۷ روز هفته در فشار بالا.

نمای کلی محصول

The LW-13/30 nitrogen compressor occupies a critical position within our oil-free piston compressor portfolio, bridging the gap between medium-capacity boosters and high-pressure process compressors. With a rated capacity of 13 m³/min و استثنایی فشار تخلیه ۳.۰۰ مگاپاسکال, this unit is purpose-built for applications where both substantial flow and elevated pressure are non-negotiable requirements.

What distinguishes the LW-13/30 from conventional alternatives is its مسیر فشرده‌سازی کاملاً بدون روغن. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely uncontaminated. This intrinsic oil-free characteristic achieves گواهینامه ISO 8573-1 کلاس 0 natively, eliminating the capital expenditure and ongoing maintenance burden of downstream oil-removal filtration systems that would be mandatory with lubricated alternatives.

معماری کمپرسور از یک two-stage, three-row (二列三级) configuration—a unique arrangement that divides the total pressure ratio across three compression cylinders arranged in two rows. This staged approach is essential for managing the extreme thermal loads associated with 3.00 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 ۱۲۰،۰۰۰ ساعت تحت پروتکل‌های استاندارد نگهداری.

Technical Specifications – LW-13/30

* 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. Three-Stage Compression for Extreme Pressure Ratios

The LW-13/30 employs a unique two-stage, three-row (二列三级) architecture that divides the extreme pressure ratio required for 3.00 MPa discharge across three compression cylinders. This multi-stage approach is thermodynamically essential because a single-stage or even two-stage compressor would generate discharge temperatures exceeding the safe operating limit of PTFE sealing materials (approximately 180°C). By splitting the compression work across three stages with two inter-stage coolers, the LW-13/30 maintains per-stage discharge temperatures below 155°C, preserving PTFE ring integrity and extending valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios. The three-row arrangement also provides improved force balance compared to single-row configurations, reducing foundation requirements.

2. High-Pressure Oil-Free PTFE Composite Sealing

The LW-13/30 utilizes a proprietary مجموعه رینگ پیستون و باند رادیال خود روان کننده manufactured from high-density PTFE composites specifically formulated for high-pressure, high-temperature service. These rings are reinforced with glass fiber and bronze particulates to achieve a coefficient of friction below 0.05 without any external hydrocarbon lubrication. At 3.00 MPa discharge pressure, the partial pressure of oil vapor would be extremely high in a lubricated compressor, making downstream oil removal virtually impossible. The oil-free design achieves انطباق با استاندارد ISO 8573-1 کلاس 0, eliminating the need for coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation that would add significant capital and operating costs to a lubricated system.

3. Reinforced Frame for High-Pressure Mechanical Loads

قاب اصلی از ریخته گری ساخته شده است چدن خاکستری GG25 with significantly reinforced wall sections, additional ribbing, and integral cooling water passages. The high-pressure cylinders feature thicker walls and enhanced structural support to withstand the peak gas forces associated with 3.00 MPa operation. The three-row arrangement distributes the mechanical loads across multiple crankshaft throws, reducing the peak bearing loads per cylinder and improving overall crankshaft longevity. The frame is dynamically analyzed using finite element modeling to ensure stress concentrations remain within safe limits under all operating conditions, including emergency shutdown transients.

4. Standard 380V Drive with High-Torque Motor

The LW-13/30 is driven by a 160 kW, 380V, 50Hz three-phase induction motor rated to IEC 60034-1 efficiency class IE3. The motor is specifically selected for high starting torque to overcome the substantial initial resistance of the three-row compression train. The standard 380V configuration integrates directly into existing low-voltage industrial distribution panels without requiring medium-voltage infrastructure, making this high-pressure compressor accessible to a wide range of industrial facilities. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied.

سناریوهای کاربردی

High-Pressure Nitrogen Injection for Enhanced Oil Recovery

In oil and gas production, the LW-13/30 serves as a کمپرسور تزریق نیتروژن فشار بالا for enhanced oil recovery (EOR) and miscible gas flooding operations. The 3.00 MPa discharge pressure is sufficient for injecting nitrogen into reservoirs at depths up to 2,000 meters, where the formation pressure requires high injection pressures to achieve effective displacement. The 13 m³/min capacity can serve multiple injection wells simultaneously through a centralized high-pressure distribution manifold. The oil-free design is critical in EOR applications because any oil contamination in the injected nitrogen would damage the reservoir formation, reduce permeability, and compromise oil recovery efficiency.

Gas Liquefaction & Cryogenic Process Booster

In nitrogen liquefaction plants and cryogenic process facilities, the LW-13/30 nitrogen booster compresses nitrogen from the liquefier cold end or storage vaporizer to the pressure required for distribution or further processing. The 3.00 MPa discharge pressure is adequate for feeding high-pressure nitrogen into cryogenic storage systems, driving nitrogen through multi-pass heat exchangers, and supplying high-pressure nitrogen for supercritical fluid extraction processes. The oil-free design prevents contamination of the cryogenic equipment, where even trace oil would freeze and block heat exchanger passages, causing costly shutdowns and equipment damage.

Petrochemical High-Pressure Reactor Inerting

In petrochemical and chemical synthesis operations, the LW-13/30 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, and emergency depressurization. The 3.00 MPa discharge pressure is sufficient to maintain positive inert gas blankets in high-pressure reactors operating at 2.00–2.50 MPa, preventing explosive vapor formation and protecting catalyst beds from oxidation during startup and shutdown. The 13 m³/min capacity can serve multiple reactors or process units through a centralized high-pressure nitrogen header. The oil-free certification is mandatory because any oil contamination would poison catalysts, degrade product quality, and create safety hazards in oxygen-sensitive processes.

آزمایش و راه‌اندازی خط لوله فشار قوی

Natural gas pipelines, petrochemical process piping, and high-pressure vessel systems require nitrogen for hydrostatic testing, pneumatic testing, and commissioning purge operations. The LW-13/30’s 3.00 MPa discharge pressure is suitable for pressure testing systems rated up to 2.50 MPa design pressure (with appropriate safety margins per ASME B31.3). The 13 m³/min capacity allows rapid pressurization of large-diameter pipelines and vessels, reducing commissioning time. The oil-free design ensures that test nitrogen does not introduce contaminants that would require post-test cleaning or compromise the integrity of sensitive process systems.

مواد و ساخت و ساز

The LW-13/30 is constructed from premium materials selected for extreme 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. سیستم‌های لوله‌کشی فشار بالا از فولاد ضد زنگ بدون درز SS316 با اتصالات فلنجی ANSI Class 900 ساخته می‌شوند تا از عدم نشتی در فشار عملیاتی 3.00 مگاپاسکال اطمینان حاصل شود.

دستورالعمل‌های نصب و نگهداری

الزامات فونداسیون و سازه

The LW-13/30 has a dry weight of 6.60 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the three-row design, the opposed-cylinder arrangement provides reasonable force balance, permitting installation on a reinforced concrete inertia block of 10–12 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz). 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. The high-pressure discharge piping must be properly supported with spring hangers or flexible supports to prevent thermal expansion stress and vibration-induced fatigue at 3.00 MPa.

طراحی سیستم آب خنک کننده

تقاضای آب خنک کننده تقریباً است 25 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and two intercoolers in parallel. Given the extreme pressure ratio, both intercoolers are critical for thermal management and must receive priority cooling water flow. 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 and chemical treatment is strongly recommended for all installations.

برنامه نگهداری پیشگیرانه

The oil-free design of the LW-13/30 dramatically reduces maintenance complexity 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 three-stage design distributes wear more evenly than two-stage configurations, reducing the frequency of major overhauls.

گواهینامه‌های انطباق و ایمنی

The LW-13/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

تحلیل عملکرد و کارایی

The LW-13/30 achieves a specific power consumption of approximately 12.31 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is highly competitive and significantly superior to diaphragm compressors, which are the primary alternative for oil-free high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 13.0–15.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.

Over an 8,000-hour annual operating cycle, the LW-13/30’s efficiency advantage versus less efficient alternatives yields approximately 52,000–104,000 kWh of annual energy savings. At $0.08/kWh, this represents $4,160–$8,320 in direct electricity cost reduction per year. However, the primary economic justification for the LW-13/30 is typically the elimination of oil-related consumables and the avoidance of downstream oil-removal equipment that would be mandatory with lubricated alternatives. The هزینه کل مالکیت برای فشرده سازی نیتروژن با فشار فوق العاده بالا is reduced by an estimated 25–35% over a 10-year operational life when oil-free operation is compared to lubricated systems with full downstream purification.

The absence of oil in the compression path is particularly valuable at 3.00 MPa because oil contamination becomes exponentially more concentrated and more difficult to remove as pressure increases. At this pressure level, even advanced coalescing filters and activated carbon systems struggle to achieve sub-ppm oil content, and the energy penalty of operating such systems becomes substantial. The LW-13/30’s native oil-free design eliminates this challenge entirely.

قابلیت‌های سفارشی‌سازی و نصب‌شده

We offer extensive customization options to adapt the LW-13/30 to specific site conditions, integration requirements, and end-user specifications:

• بسته‌های آماده تحویل با نصب روی شاسی: Pre-assembled compressor, motor, intercoolers, aftercooler, high-pressure discharge piping, instrumentation, and control panel on a structural steel skid. Factory pre-testing of all systems reduces commissioning time by 60%.
• پیکربندی‌های منطقه خطرناک: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks.
• کنترل فرآیند پیشرفته: Siemens S7-1200 or Allen-Bradley CompactLogix PLC with 10-inch HMI touchscreen, remote monitoring via Modbus TCP/IP or OPC-UA, and 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).
• برچسب نصب شده و خصوصی: Custom paint colors, branded nameplates, and localized documentation for gas equipment distributors and system integrators.

پیکربندی‌های سفارشی از [نام شرکت/شرکت/...] در دسترس هستند. حداقل سفارش ۱ واحد. Engineering proposals are typically delivered within 5–7 business days. Standard delivery time is 12–14 weeks; repeat orders are delivered in 8–10 weeks.

Case Study: LNG Plant Nitrogen Purge & Inerting System

مشتری: An LNG regasification terminal in Southeast Asia

چالش: The terminal required a reliable high-pressure nitrogen supply for pipeline purging, storage tank inerting, and emergency nitrogen injection into the LNG vaporization system. The existing oil-lubricated compressor was experiencing oil carryover into the nitrogen stream, contaminating the cryogenic heat exchangers and requiring quarterly cleaning shutdowns. The 2.50 MPa discharge pressure was also insufficient for the new high-pressure pipeline purge requirements. Maintenance costs had reached $95,000/year and unplanned shutdowns were occurring every 3–4 months.

راه حل: ما عرضه کردیم LW-13/30 oil-free nitrogen compressor as the primary high-pressure supply, configured on a custom skid with integrated dual intercoolers, aftercooler, and a Siemens S7-1200 PLC control panel with SCADA integration. The 3.00 MPa discharge pressure met all pipeline purge and tank inerting requirements. The oil-free design eliminated heat exchanger contamination. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from the intermittent purge operations.

نتایج کمی پس از ۲۴ ماه:

• میزان نیتروژن روغن: Reduced from 2.8 mg/m³ to <0.01 mg/m³, achieving ISO 8573-1 Class 0
• Cryogenic heat exchanger cleaning frequency: Reduced from quarterly to annually, saving $45,000/year
• Unplanned shutdowns: صفر رویداد in 24 months versus 6 events in the previous 24 months
• هزینه نگهداری سالانه: کاهش یافته توسط 48% ($95,000 to $49,400)
• Pipeline purge capability: Enhanced from 2.50 MPa to 3.00 MPa, meeting new regulatory requirements

“The LW-13/30 has been the most reliable piece of equipment in our nitrogen system. The elimination of oil contamination has solved our heat exchanger fouling problem, and the 3.00 MPa pressure gives us the purge capability we need for regulatory compliance. Our operations team finally has confidence in the nitrogen supply.” — Operations Manager, LNG Terminal

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 Ultra 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