کمپرسور نیتروژن LW-20/18 – بوستر نیتروژن بدون روغن با فشار بالا برای کاربردهای صنعتی 1.80 مگاپاسکال

کمپرسور نیتروژن پیستونی دو مرحله‌ای و دو ردیفه بدون روغن LW-20/18 که برای ارائه دبی 20 متر مکعب در دقیقه با فشار تخلیه 1.80 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 روان‌کننده، با قابلیت کار مداوم و بهینه شده برای عملیات صنعتی با فشار بالا و پایدار.

نمای کلی محصول

The LW-20/18 nitrogen compressor occupies a specialized position within our oil-free piston compressor portfolio, engineered for applications where elevated discharge pressure is the defining operational requirement. With a rated capacity of 20 m³/min و استثنایی 1.80 MPa discharge pressure, this unit bridges the gap between medium-pressure nitrogen distribution and high-pressure process gas applications that demand substantial flow at elevated pressure.

What fundamentally distinguishes the LW-20/18 from conventional alternatives is its completely oil-free compression mechanism. The piston rings and rider bands are fabricated from self-lubricating PTFE composite materials that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains entirely free of oil contamination. This intrinsic oil-free characteristic is indispensable for applications requiring گواهینامه ISO 8573-1 کلاس 0, including high-pressure food packaging nitrogen, pharmaceutical gas cylinder filling, and electronics-grade process gas supply where even trace oil contamination would compromise product integrity.

معماری کمپرسور از یک ... پیروی می‌کند دو مرحله ای، دو ردیفی (二列二级) configuration that is thermodynamically optimized for the high pressure ratio demanded by 1.80 MPa discharge. By distributing the pressure ratio across two compression cylinders, the LW-20/18 manages the substantial thermal loads associated with high-pressure compression while preserving the integrity of the PTFE sealing elements. Each stage incorporates an independent high-efficiency intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-load 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-20/18

* All specifications are rated at standard reference conditions (ISO 1217, Annex C). Actual performance may vary based on site altitude, ambient temperature, and inlet conditions. Power rating 240(250) kW indicates standard 240 kW with optional 250 kW motor available.

ویژگی‌های کلیدی و مزایای مهندسی

1. High-Pressure Oil-Free PTFE Sealing Technology

The LW-20/18 employs a proprietary مجموعه رینگ پیستون و باند رادیال خود روان کننده manufactured from high-density 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 high-pressure formulation maintains dimensional stability and sealing integrity at the elevated temperatures associated with 1.80 MPa discharge, ensuring انطباق با استاندارد ISO 8573-1 کلاس 0 without downstream oil-filtration equipment. For high-pressure gas cylinder filling and process gas applications, this intrinsic purity is non-negotiable.

۲. فشرده‌سازی دو مرحله‌ای برای نسبت‌های فشار بسیار بالا

The معماری فشرده‌سازی دو مرحله‌ای of the LW-20/18 is thermodynamically essential for managing the extreme pressure ratio required to achieve 1.80 MPa discharge from near-atmospheric inlet. By dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor limits the mean effective temperature per stage to manageable levels. A dedicated high-performance shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 160°C even at maximum continuous load. This thermal management is critical for preserving PTFE ring integrity under high-pressure conditions and extends valve plate service life by approximately 45% compared to single-stage designs attempting equivalent pressure ratios.

3. Reinforced Frame for High-Pressure Operation

قاب اصلی از ریخته گری ساخته شده است GG30 gray cast iron (upgraded from GG25 for high-pressure models) with thicker wall sections and integral cooling water passages. The آرایش دو ردیفه سیلندرهای مخالف provides natural first-order force cancellation, which is particularly important at the higher gas forces generated by 1.80 MPa discharge pressure. This mechanical balance reduces the unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs, permitting installation on a reinforced concrete inertia block of 8–10 tonnes despite the high-pressure operational loads. The compact dimensions—2500 × 1600 × 2700 mm—are remarkable for a high-pressure compressor of this capacity, enabling installation in existing machinery rooms without extensive civil modifications.

4. Flexible Voltage Configuration for Industrial Integration

The LW-20/18 is driven by a 240(250) kW induction motor available in 380V, 6kV, or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The standard 380V option suits facilities with existing low-voltage distribution infrastructure, while the 6kV and 10kV configurations enable direct integration into medium-voltage industrial bus systems without step-down transformers. This electrical flexibility is particularly valuable for large petrochemical complexes and steel mills where 6kV or 10kV distribution is standard, reducing electrical infrastructure costs and improving overall energy efficiency by minimizing I²R losses in power cabling.

سناریوهای کاربردی

High-Pressure Nitrogen Cylinder Filling Stations

The LW-20/18 is ideally suited for industrial gas cylinder filling operations where nitrogen must be compressed to 1.80 MPa (or higher with cascade filling) for charging standard industrial gas cylinders. Its 20 m³/min capacity supports a high-throughput filling station capable of charging 50–80 cylinders per hour, depending on cylinder size and initial pressure. The oil-free design is critical in cylinder filling because any oil contamination would remain in the cylinder and be delivered to the end-user, potentially contaminating sensitive processes in food, pharmaceutical, and electronics applications. The LW-20/18 high-pressure nitrogen compressor ensures every cylinder meets ISO 8573-1 Class 0 purity standards without additional purification steps.

Petrochemical High-Pressure Process Nitrogen

In petrochemical and refinery operations, the LW-20/18 provides high-pressure nitrogen for reactor pressure testing, catalyst regeneration, emergency nitrogen injection into high-pressure vessels, and pipeline pressure testing. The 1.80 MPa discharge pressure is sufficient to pressure-test vessels and pipelines rated to 1.5 MPa working pressure (per ASME B31.3 hydrotest requirements at 1.5× design pressure). The oil-free certification is mandatory for applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free. The continuous-duty rating ensures reliable nitrogen availability during extended turnaround campaigns.

High-Pressure VPSA Nitrogen Boosting

For VPSA nitrogen generators producing high-purity nitrogen at near-atmospheric pressure, the LW-20/18 compresses the low-pressure product to 1.80 MPa for high-pressure distribution. This elevated pressure is particularly valuable for VPSA installations serving multiple high-pressure consumers through a centralized header, where the substantial pressure losses across the distribution network must be overcome. The oil-free compression path is absolutely essential because hydrocarbon contamination would irreversibly poison the carbon molecular sieve adsorbent, permanently degrading separation efficiency and requiring costly adsorbent replacement.

Food & Beverage High-Pressure Nitrogen Injection

Large-scale beverage bottling facilities and food processing plants require high-pressure nitrogen for container pressurization, nitrogen dosing, and controlled atmosphere storage. The LW-20/18’s 1.80 MPa discharge pressure provides the head necessary for high-speed nitrogen dosing into beverage containers before capping, preventing oxygen ingress and extending product shelf life. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-contact nitrogen, eliminating any risk of oil contamination affecting product taste, appearance, or safety.

مواد و ساخت و ساز

The LW-20/18 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-20/18 has a dry weight of 4.20 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the high-pressure operational loads, the two-row opposed-cylinder design provides excellent force balance, 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 to adjacent structures. 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 coolers.

برنامه نگهداری پیشگیرانه

The oil-free design of the LW-20/18 dramatically simplifies maintenance 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 PTFE, which typically achieve 3,500–5,500 hours of service life under clean nitrogen conditions at high pressure. This maintenance simplification translates to lower labor costs, reduced spare parts inventory, and higher equipment availability.

گواهینامه‌های انطباق و ایمنی

The LW-20/18 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

تحلیل عملکرد و کارایی

The LW-20/18 achieves a specific power consumption of approximately 12.0–12.5 kW per m³/min of nitrogen delivered at 1.80 MPa discharge pressure. This efficiency metric is expected for an oil-free piston compressor operating at an extreme pressure ratio (approximately 18:1 from atmospheric inlet), and it compares favorably to diaphragm compressors that are often selected for high-pressure oil-free applications but can consume 15–20 kW/m³/min. For comparison, oil-lubricated reciprocating compressors in similar high-pressure service typically consume 11–13 kW/m³/min but introduce unacceptable oil contamination risk.

Over a standard 8,000-hour annual operating schedule, the LW-20/18’s efficiency advantage versus diaphragm alternatives generates approximately 48,000–120,000 kWh of annual energy savings. At an average industrial electricity tariff of $0.08/kWh, this represents $3,840–$9,600 in direct operating cost reduction per year. However, the primary economic driver for LW-20/18 selection is typically the elimination of oil-related consumables and the avoidance of downstream purification equipment rather than marginal energy savings.

The total cost of ownership for high-pressure nitrogen compression is further reduced by the absence of oil in the compression path. A typical oil-lubricated high-pressure compressor requires coalescing filters, activated carbon adsorbers, and continuous oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output and require significant capital investment. The LW-20/18’s oil-free design removes this parasitic load and capital expense entirely.

قابلیت‌های سفارشی‌سازی و نصب‌شده

We offer comprehensive customization options to adapt the LW-20/18 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. This approach reduces field installation time by approximately 60% and minimizes commissioning risks through factory pre-testing of all systems.
• Cylinder Filling Packages: Optional integrated cylinder filling manifold with pressure sequencing valves, cylinder pressure monitoring, and automatic filling shutoff. Compatible with standard industrial gas cylinder sizes (40L, 50L, 80L) and high-pressure tube trailers.
• پیکربندی‌های منطقه خطرناک: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for installations in petrochemical facilities where explosive atmospheres may occasionally be present. 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 integration with plant DCS/SCADA systems. Automatic load/unload control and variable frequency drive (VFD) compatibility optimize part-load efficiency.
• سیستم‌های حفاظت از محیط زیست: C5-M marine-grade coating systems for coastal installations; tropicalized electrical components for ambient temperatures up to 55°C; and IP54-rated acoustic enclosures reducing noise emission from 86 dB(A) to 73 dB(A) at 1 meter.
• برنامه‌های OEM و برچسب خصوصی: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators.

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: Industrial Gas Cylinder Filling Station Modernization

مشتری: A regional industrial gas supplier operating a cylinder filling facility in Thailand

چالش: The client’s existing high-pressure nitrogen compressor (oil-lubricated reciprocating, 20 years in service) was experiencing progressive oil carryover into filled cylinders, resulting in customer complaints from electronics manufacturers and pharmaceutical companies. Oil contamination levels in filled cylinders reached 3.5 mg/m³, far exceeding the 0.1 mg/m³ specification. The aging compressor also suffered from frequent valve failures and piston ring blow-by, causing unplanned downtime averaging 12 hours per month and reducing filling capacity by 15%.

راه حل: ما عرضه کردیم LW-20/18 oil-free nitrogen compressor with an integrated cylinder filling manifold, configured on a custom skid with a Siemens S7-1200 PLC control panel and automatic pressure sequencing. The 1.80 MPa discharge pressure enabled direct filling of 40L and 50L cylinders to 15 MPa working pressure through a three-stage cascade system. The oil-free design eliminated the need for post-filling purification and guaranteed ISO 8573-1 Class 0 compliance in every cylinder.

Quantified Results After 18 Months:

• Cylinder oil content: Reduced from 3.5 mg/m³ to <0.01 mg/m³، اخذ گواهینامه ISO 8573-1 کلاس 0
• Customer complaints: کاملاً حذف شد; zero rejected cylinders from electronics and pharmaceutical clients
• Filling capacity: Increased by 18% due to elimination of unplanned downtime and improved compressor reliability
• هزینه نگهداری سالانه: Reduced by 52% ($42,000 to $20,160) through elimination of oil-related repairs and valve failures
• خرابی‌های برنامه‌ریزی نشده: صفر رویداد in 18 months of continuous operation

“The LW-20/18 has completely transformed our cylinder filling operation. Our customers no longer reject cylinders for oil contamination, and our maintenance team has gone from fighting breakdowns to performing scheduled preventive maintenance. The integrated filling manifold has also reduced our labor requirements by 30%.” — Operations Director, Industrial 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.

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