کمپرسور نیتروژن LW-42/10 – بوستر نیتروژن بدون روغن با فشار بالا برای کاربردهای صنعتی 1.00 مگاپاسکال

Engineered to deliver 42 m³/min at 1.00 MPa discharge pressure, the LW-42/10 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure cryogenic air separation, demanding VPSA nitrogen boosting, and critical petrochemical pipeline distribution. Zero lubricant contamination, continuous-duty rated, and optimized for 24/7 operation at elevated pressure.

نمای کلی محصول

The LW-42/10 nitrogen compressor represents a specialized high-pressure solution within our oil-free piston compressor portfolio, engineered for industrial applications where both substantial flow and elevated discharge pressure are non-negotiable requirements. With a rated capacity of 42 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-42/10 from 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 completely free of oil contamination. This intrinsic oil-free characteristic delivers گواهینامه ISO 8573-1 کلاس 0 natively, eliminating the need for downstream oil-removal filtration systems that would otherwise be mandatory in food processing, pharmaceutical manufacturing, semiconductor fabrication, and petrochemical applications.

معماری کمپرسور از یک ... پیروی می‌کند دو مرحله ای، دو ردیفی (二列二级) configuration that is essential for managing the thermodynamic demands of 1.00 MPa discharge pressure. By dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the LW-42/10 achieves controlled per-stage discharge temperatures that preserve 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-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-42/10

* 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

۱. فناوری آب‌بندی کامپوزیت PTFE با دمای بالا

The LW-42/10 employs a proprietary مجموعه رینگ پیستون و باند رادیال خود روان کننده manufactured from high-performance PTFE composites reinforced with glass fiber, carbon fiber, and bronze particulates. This advanced material formulation achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover into the nitrogen product stream. Critically, the PTFE composite is specifically engineered for the elevated discharge temperatures associated with 1.00 MPa operation, maintaining dimensional stability and sealing integrity up to 200°C. For industrial gas operators, this delivers انطباق با استاندارد ISO 8573-1 کلاس 0 without downstream filtration capital costs or energy penalties.

2. High-Pressure Two-Stage Thermodynamic Optimization

The معماری فشرده‌سازی دو مرحله‌ای of the LW-42/10 is thermodynamically optimized for the demanding 1.00 MPa discharge pressure target. 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 compared to single-stage designs. A dedicated 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 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 operating at equivalent pressure ratios.

3. Reinforced Cast-Iron Frame for High-Pressure Service

قاب اصلی از ریخته گری ساخته شده است چدن خاکستری GG25 (equivalent to ASTM A48 Class 30B) with thicker wall sections and integral cooling water passages specifically designed for the mechanical stresses of 1.00 MPa discharge pressure. 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 permits installation on a reinforced concrete inertia block of 10–12 tonnes, significantly reducing civil engineering costs compared to the 18+ tonne foundations required for equivalent single-row high-pressure compressors.

4. Flexible Voltage Configuration for Industrial Integration

The LW-42/10 is driven by a 315 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 plants with medium-voltage bus systems. This electrical adaptability reduces infrastructure costs, minimizes power transmission losses, and simplifies commissioning.

سناریوهای کاربردی

High-Pressure Cryogenic Air Separation Distribution

In large cryogenic ASU facilities producing high-purity gaseous nitrogen, the LW-42/10 serves as the primary high-pressure nitrogen booster for distribution networks requiring 1.00 MPa header pressure. The 42 m³/min capacity aligns with the output of medium-to-large ASUs, while the elevated discharge pressure overcomes significant pipeline friction losses over long distribution distances. This is particularly valuable in integrated industrial complexes where nitrogen must be transported 3–5 km from the ASU to downstream consumers such as steel mills, chemical plants, and LNG facilities. The oil-free design ensures that nitrogen purity is preserved throughout the distribution chain.

ایستگاه‌های تقویت فشار بالای نیتروژن VPSA

برای ژنراتورهای بزرگ نیتروژن VPSA که نیتروژن با خلوص ۹۹.۵-۹۹.۹۱TP3T را در فشار نزدیک به اتمسفر تولید می‌کنند، LW-42/10 nitrogen booster compresses the low-pressure product to 1.00 MPa for high-pressure distribution. The elevated discharge pressure is essential for VPSA installations serving multiple consumers through extensive distribution networks where pressure losses are significant. The oil-free compression path is absolutely critical in VPSA service because hydrocarbon contamination would permanently poison the carbon molecular sieve adsorbent, degrading separation efficiency and necessitating costly adsorbent replacement that could exceed $50,000 for a large VPSA unit.

Petrochemical High-Pressure Reactor Inerting

In petrochemical and refining operations, the LW-42/10 provides high-pressure nitrogen for reactor inerting during catalyst changeout, emergency vessel purging, and high-pressure pipeline displacement. The 1.00 MPa discharge pressure is sufficient to overcome the pressure ratings of typical high-pressure process vessels and reactor systems, allowing direct nitrogen injection without intermediate boosting. This capability is particularly valuable during emergency shutdown procedures where rapid nitrogen inerting is required to prevent explosive atmosphere formation in process equipment operating at elevated pressures.

High-Pressure Food Packaging & Aseptic Processing

Large-scale food and beverage facilities utilizing high-pressure aseptic processing, HPP (High Pressure Processing) pre-treatment nitrogen pressurization, and high-speed modified atmosphere packaging require nitrogen at elevated pressures. The LW-42/10’s 1.00 MPa discharge pressure supports high-pressure nitrogen injection into aseptic filling lines and HPP vessels, while its oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012. The 42 m³/min capacity can simultaneously supply multiple high-speed packaging lines and aseptic processing stations.

مواد و ساخت و ساز

The LW-42/10 is constructed from premium materials selected for high-pressure nitrogen compatibility, corrosion 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-42/10 has a dry weight of 6.00 tonnes and a center of gravity approximately 950 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 reinforced concrete inertia block of 10–12 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 48 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-42/10 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 PTFE, which typically achieve 4,000–6,000 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-42/10 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

تحلیل عملکرد و کارایی

The LW-42/10 achieves a specific power consumption of approximately 7.50 kW per m³/min of nitrogen delivered at 1.00 MPa discharge pressure. This efficiency metric is commendable for an oil-free piston compressor operating at a high pressure ratio, positioning the unit competitively within the 30–50 m³/min high-pressure capacity class. For comparison, oil-lubricated screw compressors in similar high-pressure applications typically consume 7.8–8.8 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-42/10’s efficiency advantage generates approximately 96,000–240,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $7,680–$19,200 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 is reduced by an estimated 20–28% over a 10-year operational life.

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 and pressure rating requires coalescing filters, activated carbon adsorbers, and continuous oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output. The LW-42/10’s oil-free design removes this parasitic load entirely, further improving effective system efficiency.

قابلیت‌های سفارشی‌سازی و نصب‌شده

We offer comprehensive customization options to adapt the LW-42/10 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 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.
• 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: اختیاری Siemens S7-1200 یا Allen-Bradley CompactLogix PLC با صفحه لمسی 10 اینچی HMI، نظارت از راه دور از طریق Modbus TCP/IP یا OPC-UA، و ادغام یکپارچه با سیستم‌های DCS/SCADA کارخانه. کنترل خودکار بارگیری/تخلیه بار و سازگاری با درایو فرکانس متغیر (VFD)، راندمان بار جزئی را بهینه کرده و سایش مکانیکی را در هنگام راه اندازی کاهش می‌دهد.
• 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 87 dB(A) to 73 dB(A) at 1 meter, suitable for indoor installations without dedicated compressor houses.
• 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: High-Pressure Aseptic Food Processing Upgrade

مشتری: A major dairy products manufacturer in Southeast Asia with multiple aseptic filling lines

چالش: The client’s existing nitrogen supply consisted of two oil-lubricated compressors (Japanese brand, 12 years in service) feeding a 0.60 MPa distribution header. The facility was upgrading to high-pressure aseptic filling technology requiring 0.90–1.00 MPa nitrogen for pre-sterilization and overpressure protection. The existing compressors could not achieve the required pressure, and oil contamination from the lubricated compressors had caused multiple aseptic line shutdowns due to oil deposits on packaging film.

راه حل: ما عرضه کردیم LW-42/10 oil-free nitrogen compressor as the primary high-pressure nitrogen source, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel with SCADA integration. The 1.00 MPa discharge pressure met the new aseptic filling requirements, while the oil-free design eliminated contamination of packaging materials. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from the intermittent aseptic line operations.

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
• Aseptic line shutdowns due to oil contamination: کاملاً حذف شد, improving line availability by 3.5%
• هزینه نگهداری سالانه: Reduced by 40% through elimination of oil-related repairs and filter replacements
• High-pressure aseptic filling capability: Successfully commissioned, enabling new product line expansion
• خرابی‌های برنامه‌ریزی نشده: صفر رویداد in 18 months of continuous operation

“The LW-42/10 enabled our high-pressure aseptic filling upgrade while eliminating the oil contamination that had plagued our previous compressors. Our packaging quality has improved dramatically, and we have not experienced a single nitrogen-related line shutdown since installation.” — Production Director, Dairy Products Manufacturer

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