Description
LW-5.3/16 Nitrogen Compressor – High-Pressure Oil-Free N2 Booster for Demanding Industrial Applications
Engineered to deliver 5.3 m³/min at 1.60 MPa discharge pressure, the LW-5.3/16 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, gas cylinder filling, and specialized petrochemical inerting operations. Zero oil contamination, compact footprint, and optimized for medium-duty industrial service at elevated pressure.
Présentation du produit
Le LW-5.3/16 nitrogen compressor occupies a specialized niche within our oil-free piston compressor portfolio, engineered for applications that demand both moderate flow capacity and significantly elevated discharge pressure. With a rated capacity of 5.3 m³/min and an impressive 1.60 MPa discharge pressure, this unit bridges the gap between conventional low-pressure nitrogen boosters and ultra-high-pressure gas filling systems.
What distinguishes the LW-5.3/16 is its mécanisme de compression entièrement sans huile 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-grade inerting, and electronics manufacturing where even trace oil content would compromise product integrity. The native oil-free certification achieves Conformité à la norme ISO 8573-1, classe 0 without requiring additional downstream purification equipment.
C'est à deux étages, à deux rangées (二列二级) configuration is thermodynamically optimized for the high pressure ratio required to reach 1.60 MPa. The staged compression approach divides the total pressure burden between a low-pressure cylinder and a high-pressure cylinder, with an inter-stage cooler removing the heat of compression to maintain gas temperatures within safe limits. This thermal management is critical for preserving the integrity of the PTFE sealing elements under the demanding conditions of high-pressure operation. The compact dimensions—1947 × 1900 × 2580 mm—and manageable weight of 3.97 tonnes make the LW-5.3/16 suitable for installations where space is at a premium.
Technical Specifications – LW-5.3/16
| Paramètre | Valeur | Unité |
|---|---|---|
| Modèle | LW-5,3/16 | – |
| Modèle | À deux étages, à deux rangées (二列二级) | – |
| Capacité | 5.3 | m³/min |
| Pression de refoulement | 1.60 | MPa |
| Dimensions du compresseur (L × l × H) | 1947 × 1900 × 2580 | mm |
| Poids | 3.97 | t |
| Pouvoir | 55 | kW |
| Tension | 380 | V |
| Gaz moyen | Azote (N₂) | – |
| Lubrification | Sans huile | – |
* Toutes les spécifications sont données dans des conditions de référence standard (ISO 1217, annexe C). Les performances réelles peuvent varier en fonction de l'altitude du site, de la température ambiante et des conditions d'entrée.
Principales caractéristiques et avantages techniques
1. High-Pressure Oil-Free PTFE Sealing Technology
The LW-5.3/16 employs a specialized système de segment de piston et de bande de guidage autolubrifiants manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. This material formulation is specifically engineered for high-pressure service, achieving a coefficient of friction below 0.08 without any external hydrocarbon lubrication. The rings are dimensionally stable at temperatures up to 180°C, which is essential for managing the thermal loads associated with 1.60 MPa discharge pressure. For operators requiring high-purity nitrogen, this design delivers Conformité native à la norme ISO 8573-1 Classe 0, eliminating the need for costly downstream oil-filtration systems.
2. Two-Stage Compression for Extreme Pressure Ratios
Le architecture de compression à deux étapes is indispensable for achieving the 1.60 MPa discharge pressure from typical inlet conditions of 0.05–0.10 MPa. By dividing the overall pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the LW-5.3/16 maintains manageable discharge temperatures per stage. A dedicated high-efficiency shell-and-tube intercooler between stages removes the heat of compression, keeping gas temperatures below 160°C even at maximum continuous load. This thermal management strategy is critical for preserving PTFE ring integrity under high-pressure conditions and extends valve plate service life by approximately 35% compared to single-stage designs attempting equivalent pressure ratios.
3. Compact Design with Robust Construction
Despite its high-pressure capability, the LW-5.3/16 maintains a remarkably compact footprint of 1947 × 1900 × 2580 mm. This dimensional efficiency is achieved through a vertically oriented crankcase design that minimizes longitudinal space requirements while providing adequate maintenance access. The main frame is cast from fonte grise GG25 with integral cooling water passages, and the two-row opposed-cylinder arrangement provides natural first-order force cancellation. At 3.97 tonnes, the unit can be transported and positioned using standard forklift equipment, eliminating the need for specialized rigging during installation or relocation.
4. Variateur de fréquence standard 380 V à alimentation directe en ligne
The LW-5.3/16 is powered by a Moteur à induction triphasé de 55 kW, 380 V, 50 Hz conforming to IEC 60034-1 efficiency class IE3. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage infrastructure or step-down transformers. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the LW-5.3/16 an attractive option for facilities upgrading from high-pressure bottled nitrogen or membrane separation systems to on-site compression.
Scénarios d'application
Stations de remplissage de bouteilles d'azote haute pression
The LW-5.3/16 is ideally suited for opérations de remplissage des bouteilles d'azote where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa. The 1.60 MPa discharge pressure serves as the primary booster stage, feeding a downstream high-pressure compressor or booster pump that achieves the final cylinder charging pressure. The oil-free design is mandatory in cylinder filling applications because any oil contamination would compromise the purity of nitrogen delivered to end-users in food processing, medical, and electronics industries. The 5.3 m³/min capacity supports filling rates of 20–30 cylinders per hour, making it suitable for medium-scale filling stations serving regional industrial gas markets.
Specialized Petrochemical High-Pressure Inerting
In petrochemical operations involving high-pressure reactors, catalyst regeneration systems, and hydrocracking units, nitrogen is required at elevated pressures for reactor inerting, catalyst preservation, and emergency depressurization. The LW-5.3/16 high-pressure nitrogen compressor delivers the 1.60 MPa pressure necessary to overcome reactor operating pressures and maintain positive inert gas flow. The oil-free certification is critical in these applications because any hydrocarbon contamination would poison precious metal catalysts, degrade product quality, and create safety hazards in hydrogen-rich process environments.
Pharmaceutical High-Pressure Inerting & Blanketing
Pharmaceutical manufacturing facilities require high-purity nitrogen at elevated pressures for reactor blanketing, powder conveying, and sterile packaging operations. The LW-5.3/16’s 1.60 MPa discharge pressure is sufficient to drive pneumatic conveying systems that transport active pharmaceutical ingredients (APIs) between process vessels without contamination risk. The oil-free design ensures compliance with FDA 21 CFR 211.72 (equipment cleaning and maintenance) and EU GMP Annex 1 (manufacture of sterile medicinal products), where any oil contamination would render batches unfit for human use.
Electronics High-Pressure Process Gas Supply
Semiconductor fabrication facilities and electronics assembly plants require high-pressure nitrogen for wafer handling, chemical vapor deposition (CVD) chamber purging, and lead-free soldering operations. The LW-5.3/16’s 1.60 MPa pressure supports the high-flow pneumatic actuators and process gas manifolds used in advanced packaging lines. The oil-free certification is non-negotiable in electronics applications because even trace oil contamination can cause solder joint defects, delamination of conformal coatings, and catastrophic failure of sensitive optical components.
Matériaux et construction
The LW-5.3/16 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal stability, and extended service life:
| Composant | Matériel | Spécification |
|---|---|---|
| Bloc-cylindres | Fonte grise | GG25 / HT250, chemises de refroidissement d'eau intégrées |
| vilebrequin | Acier allié forgé | Acier 42CrMo4, trempé et revenu, équilibré dynamiquement selon la norme ISO 1940 G2.5 |
| segments de piston | Composite PTFE-verre-bronze | Autolubrifiant, résistant aux hautes températures jusqu'à 180 °C |
| Bandes de cavalier | Composite PTFE | Guidage du piston, protection anti-grippage, taux d'usure < 0,05 mm/1000 h |
| Plaques de soupape | Acier inoxydable | Acier inoxydable SS316, conception à ressort à anneau concentrique |
| Bielles | Acier forgé avec paliers en métal antifriction | Tête de bielle usinée avec précision et lubrifiée à l'huile |
| refroidisseur intermédiaire | Coque en acier au carbone / Tubes en acier inoxydable 316 | ASME VIII Div.1, essai hydrostatique 1,5×, maintien de 30 min |
| High-Pressure Cylinder Head | Forged Steel | Normalized, 100% UT inspected |
Tous les composants soumis à la pression sont conçus et fabriqués conformément aux normes en vigueur. ASME BPVC Section VIII Division 1 ou les normes chinoises GB 150. Chaque joint soudé subit une inspection radiographique 100% (RT) conformément à la section V, article 2 de l'ASME, et chaque récipient sous pression terminé est soumis à un essai de pression hydrostatique à 1,5 fois la pression de service maximale admissible (MAWP) pendant une période de maintien minimale de 30 minutes.
Instructions d'installation et d'entretien
Exigences en matière de fondations et d'espace
The LW-5.3/16 has a dry weight of 3.97 tonnes and a low center of gravity due to its compact vertical design. A reinforced concrete pad of 5–6 tonnes Ce système, monté sur des isolateurs de vibrations élastomères (fréquence naturelle de 8 à 12 Hz), assure un fonctionnement stable. La configuration à deux rangées de cylindres opposés annule intrinsèquement les forces d'inertie du premier ordre, minimisant ainsi la transmission des vibrations. Dégagements requis : 1,0 m côté opposé à l'entraînement pour la maintenance de la vanne, 0,8 m côté entraînement pour l'accès au moteur et 1,5 m en hauteur pour l'entretien courant.
Spécifications de l'eau de refroidissement
La demande en eau de refroidissement est d'environ 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Acceptable water quality: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride < 50 mg/L, suspended solids < 30 mg/L. For installations without reliable municipal water supply, a compact closed-loop cooling tower with a 0.5 m³ buffer tank is recommended.
Programme d'entretien préventif
| Intervalle | Article de service | Action requise |
|---|---|---|
| Tous les jours | Contrôle visuel et opérationnel | Inspect for leaks, abnormal noise, cooling water flow, discharge temperature |
| 250 heures | Inspection de la plaque de soupape | Vérifier la présence de dépôts de carbone, de signes de fatigue des ressorts ou de fissures dans les plaques. |
| 1 000 heures | Évaluation de l'usure des segments de piston | Measure groove clearance; replace rings if clearance exceeds 0.20 mm |
| 4 000 heures | Service intermédiaire | Remplacez les segments de piston, les bandes de guidage et les ensembles de soupapes. |
| 8 000 heures | Révision majeure | Inspecter le vilebrequin, mesurer le jeu des paliers et les remplacer si nécessaire. |
The oil-free design of the LW-5.3/16 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes to schedule, no oil samples to analyze, no filter elements to replace, and no separator cartridges to monitor. The only consumable wear items are the segments de piston et bagues de guidage en PTFE, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions.
Certifications de conformité et de sécurité
The LW-5.3/16 nitrogen compressor meets the following international standards and regulatory requirements:
ASME BPVC Section VIII Div.1, GB 150-2011, PED 2014/68/EU Module A
CEI 60034-1 (efficacité IE3), CEI 60204-1, ISO 12100
Conforme à la norme ISO 8573-1, classe 0 (teneur en huile), testé par TÜV Rheinland.
ISO 9001:2015, ISO 14001:2015
Nitrogen is an odorless, colorless asphyxiant gas. All LW-5.3/16 installations must include continuous oxygen monitoring in the compressor room and adjacent areas. Ventilation must maintain ambient oxygen above 19.5% per OSHA 29 CFR 1910.146. Alarm interlocks should trigger at 19.5% O₂ and hard shutdown at 18.0% O₂. Personnel entry requires portable oxygen monitors and a buddy system. High-pressure nitrogen systems require additional precautions including pressure relief devices, burst disc protection, and personnel training on high-pressure gas safety.
Analyse des performances et de l'efficacité
The LW-5.3/16 achieves a specific power consumption of approximately 10.38 kW per m³/min of nitrogen delivered at 1.60 MPa discharge pressure. While this specific power is higher than low-pressure models due to the extreme pressure ratio, it remains competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated alternatives in this pressure class typically consume 11.0–12.5 kW/m³/min, and diaphragm compressors (often selected for oil-free high-pressure service) can exceed 14 kW/m³/min.
Over an 8,000-hour annual operating cycle, the LW-5.3/16’s efficiency advantage versus less efficient alternatives yields approximately 25,000–55,000 kWh of energy savings per year. At $0.08/kWh, this represents $2,000–$4,400 in annual electricity cost reduction. However, the primary economic driver for LW-5.3/16 selection is typically the élimination des consommables liés au pétrole et des équipements de purification en aval plutôt que des économies d'énergie marginales.
Le total cost of ownership for high-pressure nitrogen compression is dominated by maintenance labor and consumables. The LW-5.3/16’s oil-free design eliminates oil changes ($300–600/year), filter replacements ($150–300/year), separator cartridge changes ($400–800/year), and oil analysis ($100–200/year), delivering total consumable savings of $950–$1,900 annually compared to lubricated alternatives.
Capacités de personnalisation et de fabrication d'équipement d'origine (OEM)
We provide flexible customization options to adapt the LW-5.3/16 to specific installation constraints and end-user requirements:
- Ensembles montés sur patins : Compresseur, moteur, refroidisseur et panneau de commande préassemblés sur un châssis en acier structurel avec passages de fourches et anneaux de levage. Réduit l'installation sur site au simple raccordement électrique et au raccordement à l'eau de refroidissement.
- Unités mobiles remorquées : The LW-5.3/16 can be mounted on a road-legal trailer with integrated diesel generator and cooling system, creating a fully mobile high-pressure nitrogen supply unit for construction sites, pipeline maintenance, and emergency response.
- Automates programmables et surveillance à distance : Automate programmable Siemens LOGO! ou S7-1200 (en option) avec écran tactile IHM 7 pouces, connectivité Ethernet et notifications d'alarme par SMS/e-mail. Compatible Modbus TCP/IP pour l'intégration SCADA.
- Enceintes acoustiques : Compact IP54-rated sound enclosure reducing noise from 84 dB(A) to 68 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments.
- OEM et marques privées : Schémas de peinture personnalisés, plaques signalétiques de marque et dossiers de documentation localisés pour les distributeurs d'équipements à gaz et les intégrateurs de systèmes.
Des configurations personnalisées sont disponibles auprès de Quantité minimale de commande : 1 unitéLes propositions d'ingénierie sont généralement livrées sous 3 à 5 jours ouvrables. Le délai de livraison standard est de 10 à 12 semaines ; une livraison express en 8 semaines est possible pour les commandes éligibles.
Case Study: Pharmaceutical Cylinder Filling Operation
Client: A pharmaceutical gas supplier in Southeast Asia specializing in medical-grade nitrogen
Défi: The client’s existing oil-lubricated high-pressure nitrogen compressor (10 years in service) was experiencing progressive oil carryover into the nitrogen product during cylinder filling operations. Oil contamination levels reached 1.5 mg/m³, far exceeding the 0.1 mg/m³ limit required for medical-grade nitrogen certification. The oil was also contaminating the cylinder filling manifold, requiring monthly cleaning and replacement of O-rings and seals.
Solution: Nous avons fourni un LW-5.3/16 oil-free nitrogen compressor as the primary booster, feeding a downstream high-pressure booster pump for final cylinder charging. The unit was mounted on a custom skid with integrated intercooler, aftercooler, and a Siemens LOGO! PLC control panel. A 1 m³ surge vessel was installed upstream to buffer pressure fluctuations from the membrane nitrogen generator supplying the compressor.
Résultats après 18 mois :
- Teneur en huile azotée : Reduced from 1.5 mg/m³ to <0.01 mg/m³, achieving ISO 8573-1 Class 0 and medical-grade certification
- Cylinder filling manifold cleaning: Eliminated, reducing labor costs by $8,000/year
- O-ring and seal replacement: Reduced by 90%, saving $3,500/year in consumables
- Charge d'entretien : Un entretien programmé par an versus quarterly overhauls
- Réclamations des clients : Zéro since commissioning, with nitrogen purity consistently exceeding specifications
“The LW-5.3/16 has been a game-changer for our medical nitrogen business. We no longer worry about oil contamination, and our customers have noticed the improved consistency in gas quality. The payback period was just over 2 years.” — Operations Manager, Pharmaceutical Gas Supplier
FAQ et guide de sélection
Produits et solutions connexes
Compresseurs d'azote haute pression série DW
Designed for discharge pressures from 0.40 MPa to 2.00 MPa, the DW series covers nitrogen injection, high-pressure pipeline boosting, and chemical synthesis applications. Capacities from 2 to 130 m³/min.
Compresseurs multi-étages sans huile série ZW
Vertical, multi-stage oil-free compressors for oxygen, nitrogen, hydrogen, and specialty gases. Discharge pressures up to 9.00 MPa for high-pressure gas filling and chemical process applications.
Compresseurs moyenne pression série MW
Medium-pressure oil-free compressors (1.0–4.0 MPa) for nitrogen recycle, gas liquefaction booster duty, and process gas compression in petrochemical operations.
Pour un aperçu complet de nos compresseur d'azote industriel Pour en savoir plus sur notre gamme de produits, notamment les compresseurs d'oxygène sans huile, les compresseurs d'hydrogène et les solutions pour gaz spéciaux, veuillez contacter notre équipe d'ingénierie ou consulter notre catalogue en ligne.
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