LW-20/8 नाइट्रोजन कंप्रेसर – निरंतर औद्योगिक संचालन के लिए मध्यम क्षमता वाला तेल-मुक्त N2 बूस्टर

Delivering 20 m³/min at 0.80 MPa discharge pressure, the LW-20/8 is a two-stage, two-row oil-free piston nitrogen compressor engineered for medium-scale cryogenic air separation, VPSA nitrogen booster stations, and industrial pipeline distribution. Zero lubricant contamination, 24/7 continuous-duty rated, and built for demanding industrial environments.

उत्पाद अवलोकन

The LW-20/8 nitrogen compressor occupies a strategic position in our oil-free piston compressor lineup, bridging the gap between compact entry-level units and large-scale industrial boosters. With a rated capacity of 20 घन मीटर/मिनट और डिस्चार्ज दबाव 0.80 एमपीए, this model serves as the backbone of medium-scale nitrogen distribution systems across cryogenic air separation, petrochemical inerting, and food processing industries.

What sets the LW-20/8 apart from conventional alternatives is its पूरी तरह से तेल-मुक्त संपीड़न मार्ग. The piston rings and rider bands are precision-machined from self-lubricating PTFE composite materials that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This native oil-free characteristic is essential for applications demanding ISO 8573-1 Class 0 certification, including food-grade nitrogen blanketing, pharmaceutical process inerting, and electronics manufacturing atmosphere control.

कंप्रेसर में एक दो-चरण, दो-पंक्ति (二列二级) architecture that thermodynamically optimizes the pressure ratio across two cylinders. Each stage is independently cooled via a dedicated intercooler, maintaining discharge temperatures within safe operating limits even during sustained 24/7 operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft are engineered for a minimum service life of 15 years मानक रखरखाव प्रोटोकॉल के तहत।

Technical Specifications – LW-20/8

* सभी विनिर्देश मानक संदर्भ स्थितियों (ISO 1217, अनुलग्नक C) के आधार पर निर्धारित किए गए हैं। वास्तविक प्रदर्शन स्थल की ऊंचाई, परिवेश के तापमान और इनलेट स्थितियों के आधार पर भिन्न हो सकता है।

मुख्य विशेषताएं और इंजीनियरिंग संबंधी लाभ

1. तेल रहित पीटीएफई कम्पोजिट सीलिंग सिस्टम

The LW-20/8 utilizes an advanced स्व-चिकनाई वाले पिस्टन रिंग और राइडर बैंड असेंबली manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material system achieves a coefficient of friction below 0.08 without any external hydrocarbon lubrication, completely eliminating the risk of oil vapor carryover into the nitrogen product stream. For regulated industries, this delivers ISO 8573-1 क्लास 0 के अनुरूप natively—without the capital expense, maintenance burden, or energy penalty of downstream oil-removal filtration systems.

2. दो-चरणीय ऊष्मागतिकीय अनुकूलन

The two-stage compression arrangement splits the overall pressure ratio between a low-pressure cylinder and a high-pressure cylinder, reducing the mean effective temperature per stage and improving volumetric efficiency. An integrated shell-and-tube intercooler removes the heat of compression between stages, maintaining discharge temperatures below 155°C even at maximum continuous load. This thermal management strategy extends valve plate service life by approximately 35% compared to single-stage designs operating at equivalent pressure ratios, while also preventing thermal degradation of the PTFE sealing elements.

3. Heavy-Duty Frame with Inherent Force Balance

The compressor block is cast from GG25 धूसर कच्चा लोहा (equivalent to ASTM A48 Class 30B) with integral cooling water passages. The two-row opposed-cylinder configuration provides natural first-order force cancellation, reducing unbalanced inertia forces transmitted to the foundation by over 80% versus single-row designs. This mechanical advantage permits installation on a lighter concrete inertia block (minimum 5 tonnes versus 8+ tonnes for single-row equivalents), reducing civil engineering costs and simplifying retrofit installations in existing compressor houses or machinery rooms.

4. मानक 380V औद्योगिक मोटर ड्राइव

The LW-20/8 is driven by a 132 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 IE3 efficiency class. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage switchgear, step-down transformers, or specialized electrical infrastructure. This simplifies both capital expenditure and commissioning timelines, making the LW-20/8 an attractive upgrade path for facilities transitioning from bottled nitrogen or membrane generators to on-site compressed nitrogen supply.

अनुप्रयोग परिदृश्य

मध्यम आकार के क्रायोजेनिक वायु पृथक्करण संयंत्र

In cryogenic ASU facilities producing 500–1,500 Nm³/h of gaseous nitrogen, the LW-20/8 serves as the प्राथमिक नाइट्रोजन बूस्टर between the cold box and the distribution header. Its 20 m³/min capacity matches the output of medium-scale ASUs, while the 0.80 MPa discharge pressure is optimized for pipeline distribution to downstream consumers such as chemical reactors, steel mill ladle inerting systems, and LNG facility purge gas networks. The oil-free design is particularly critical in ASU backup scenarios where nitrogen purity cannot be compromised during primary system maintenance or cold box upsets.

वीपीएसए नाइट्रोजन बूस्टर स्टेशन

वैक्यूम प्रेशर स्विंग एडसॉर्प्शन (वीपीएसए) नाइट्रोजन जनरेटर लगभग वायुमंडलीय दबाव (0.05–0.10 एमपीए) पर गैसीय नाइट्रोजन का उत्पादन करते हैं। LW-20/8 nitrogen booster compresses this low-pressure product to 0.80 MPa for distribution to point-of-use applications. The oil-free compression path is essential in VPSA service because any hydrocarbon contamination would poison the carbon molecular sieve adsorbent, permanently degrading the generator’s separation efficiency and necessitating costly adsorbent replacement. The 20 m³/min capacity supports medium-scale VPSA installations serving multiple industrial consumers through a centralized nitrogen header.

Petrochemical Tank Farm Blanketing & Inerting

Refinery tank farms and petrochemical storage facilities require substantial volumes of nitrogen for tank blanketing, inerting, and gas padding to prevent explosive vapor formation and maintain product quality. The LW-20/8’s continuous-duty rating and 0.80 MPa discharge pressure make it capable of serving multiple storage tanks simultaneously through a centralized nitrogen distribution header. The pressure head is sufficient to overcome tank pressure relief valve settings and maintain positive pressure during product withdrawal cycles, even in facilities with elevated tank geometries or long distribution pipelines.

Food Processing & Modified Atmosphere Packaging

Large-scale food processing facilities utilize nitrogen for modified atmosphere packaging (MAP), controlled atmosphere storage, and nitrogen sparging to extend product shelf life and maintain freshness. The LW-20/8’s 20 m³/min capacity can simultaneously supply multiple high-speed packaging lines, nitrogen-flush tunnels, and storage vaults. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-contact nitrogen, eliminating the risk of off-flavors, rancidity, or product discoloration that can occur with lubricated compressor alternatives.

सामग्री और निर्माण

Every component of the LW-20/8 is selected for nitrogen service compatibility, corrosion resistance, and long-term mechanical durability:

सभी दबाव सहन करने वाले घटकों को डिजाइन और निर्मित किया गया है। एएसएमई बीपीवीसी सेक्शन आठवीं डिवीजन 1 or Chinese GB 150 standards. Weld joints undergo 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 time of 30 minutes.

स्थापना एवं रखरखाव संबंधी दिशानिर्देश

नींव और माउंटिंग संबंधी आवश्यकताएँ

The LW-20/8 has a dry weight of 3.00 tonnes and a center of gravity approximately 820 mm above the baseplate. Thanks to the two-row opposed-cylinder design, unbalanced forces are minimal, permitting installation on a reinforced concrete inertia block of 5–6 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: 1.2 m on the non-drive side for valve access, 1.0 m on the drive side for motor maintenance, and 1.8 m overhead for crane access during major overhauls.

शीतलन जल प्रणाली की विशिष्टताएँ

Cooling water flow requirement is approximately 22 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS304 tube corrosion), and suspended solids < 30 mg/L. 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 tube fouling.

निवारक रखरखाव अनुसूची

The oil-free design of the LW-20/8 significantly reduces maintenance complexity compared to lubricated alternatives. There are no oil changes to schedule, no oil samples to analyze, no filter elements to replace, and no oil separator cartridges to monitor. The only recurring wear items are the पीटीएफई पिस्टन रिंग और राइडर बैंड, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions.

अनुपालन एवं सुरक्षा प्रमाणपत्र

The LW-20/8 nitrogen compressor is designed, manufactured, and tested to meet the following international standards and regulatory frameworks:

प्रदर्शन और दक्षता विश्लेषण

The LW-20/8 achieves a specific power consumption of approximately 6.60 kW per m³/min of nitrogen delivered at 0.80 MPa discharge pressure. This efficiency metric positions the unit competitively within the 15–30 m³/min oil-free piston compressor segment. For comparison, typical oil-lubricated screw compressors operating at equivalent pressure ratios consume 7.0–7.8 kW/m³/min, while older single-stage piston designs may exceed 8.5 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the LW-20/8’s efficiency advantage yields approximately 64,000–160,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this translates to $5,120–$12,800 in direct operating cost reduction per year. When combined with the elimination of oil-related consumables (lubricating oil, filter elements, separator cartridges, waste oil disposal), the नाइट्रोजन संपीड़न के लिए स्वामित्व की कुल लागत 10 वर्षों के परिचालन जीवनकाल में अनुमानित 20–30% की कमी हो जाती है।

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 requires coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output. The LW-20/8’s oil-free design removes this parasitic load entirely, improving overall system efficiency.

अनुकूलन और ओईएम क्षमताएं

We offer comprehensive customization options to adapt the LW-20/8 to specific site conditions, integration requirements, and end-user specifications:

• स्किड-माउंटेड टर्नकी पैकेज: 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.
• खतरनाक क्षेत्र विन्यास: पेट्रोकेमिकल संयंत्रों में जहां कभी-कभी विस्फोटक वातावरण मौजूद हो सकता है, वहां ATEX ज़ोन 2 और IECEx मानकों के अनुरूप मोटर और विद्युत आवरण उपलब्ध हैं। गैस पहचान और स्वचालित वेंटिलेशन इंटरलॉक को नियंत्रण प्रणाली में एकीकृत किया जा सकता है।
• उन्नत प्रक्रिया नियंत्रण: 10-इंच HMI टचस्क्रीन, Modbus TCP/IP या OPC-UA के माध्यम से रिमोट मॉनिटरिंग और सहज DCS/SCADA एकीकरण के साथ वैकल्पिक सीमेंस S7-1200 या एलन-ब्रैडली कॉम्पैक्टलॉजिक्स पीएलसी उपलब्ध है। स्वचालित लोड/अनलोड नियंत्रण और वेरिएबल स्पीड ड्राइव (VFD) संगतता आंशिक लोड दक्षता को बेहतर बनाती है।
• पर्यावरण संरक्षण: तटीय या अपतटीय प्रतिष्ठानों के लिए C5-M समुद्री-ग्रेड कोटिंग सिस्टम; 55°C तक के परिवेश तापमान के लिए उष्णकटिबंधीय विद्युत घटक; और IP54-रेटेड ध्वनिक आवरण जो 1 मीटर पर शोर उत्सर्जन को 85 dB(A) से घटाकर 72 dB(A) कर देते हैं।
• ओईएम और प्राइवेट लेबल: सिस्टम इंटीग्रेटर्स और गैस उपकरण वितरकों के लिए अनुकूलित पेंट रंग, ब्रांडेड नेमप्लेट और दस्तावेज़ीकरण पैकेज उपलब्ध हैं। तकनीकी मैनुअल, स्पेयर पार्ट्स की सूची और रखरखाव प्रक्रियाएं स्थानीय भाषाओं में उपलब्ध कराई जा सकती हैं।

अनुकूलित कॉन्फ़िगरेशन यहां से उपलब्ध हैं न्यूनतम मात्रा 1 इकाईइंजीनियरिंग समीक्षा और प्रस्ताव तैयार करने में आमतौर पर 5-7 कार्यदिवस लगते हैं। प्रोटोटाइप की डिलीवरी का समय 12-14 सप्ताह होता है; दोहराए गए ऑर्डर की डिलीवरी ऑर्डर की पुष्टि के बाद 8-10 सप्ताह में की जाती है।

Case Study: Food Packaging Nitrogen Supply Upgrade

ग्राहक: A major snack food manufacturer in Thailand

चुनौती: The manufacturer was relying on liquid nitrogen vaporization for their modified atmosphere packaging (MAP) lines. Rising liquid nitrogen prices, delivery scheduling conflicts, and vaporizer maintenance issues were causing production delays. Additionally, the existing lubricated nitrogen booster (competitor brand) was introducing trace oil contamination that caused off-flavors in sensitive product lines, resulting in customer complaints and product recalls.

समाधान: हमने आपूर्ति की LW-20/8 oil-free nitrogen compressor paired with a medium-scale VPSA nitrogen generator (99.9% purity, 25 m³/min) on a common skid. The LW-20/8 boosts the VPSA product from 0.08 MPa to 0.80 MPa for distribution to six high-speed packaging lines. The skid was designed to fit within the existing utility room, eliminating the need for building expansion.

24 महीनों के बाद प्राप्त मात्रात्मक परिणाम:

• नाइट्रोजन आपूर्ति लागत: Reduced by 48% versus liquid nitrogen purchase and delivery
• Oil contamination in nitrogen: पूरी तरह से समाप्त (ISO 8573-1 Class 0 achieved)
• Product recall incidents: Zero since commissioning (previously 2–3 per year)
• Maintenance expenditure: 35% से कमी आई तेल बदलने, फिल्टर बदलने और सेपरेटर की मरम्मत करने की आवश्यकता समाप्त होने के कारण
• Production downtime: Reduced by 60% (no more liquid nitrogen delivery scheduling conflicts)
• वापसी की अवधि: 2.1 years based on gas cost savings and avoided recall costs

“The LW-20/8 compressor has completely transformed our nitrogen supply. We no longer worry about liquid nitrogen deliveries, our product quality issues have disappeared, and our maintenance team spends far less time on compressor upkeep. The investment paid for itself in just over two years.” — प्लांट इंजीनियरिंग मैनेजर

अक्सर पूछे जाने वाले प्रश्न और चयन मार्गदर्शिका

संबंधित उत्पाद और समाधान

हमारे बारे में विस्तृत जानकारी के लिए औद्योगिक नाइट्रोजन कंप्रेसर हमारे पोर्टफोलियो में तेल-मुक्त ऑक्सीजन कंप्रेसर, हाइड्रोजन कंप्रेसर, कार्बन डाइऑक्साइड कंप्रेसर और कस्टम-इंजीनियर्ड स्पेशलिटी गैस समाधान शामिल हैं। अधिक जानकारी के लिए, कृपया हमारी एप्लीकेशन इंजीनियरिंग टीम से संपर्क करें या हमारी ऑनलाइन उत्पाद सूची देखें।

क्या आप अपने नाइट्रोजन संपीड़न प्रणाली को अनुकूलित करने के लिए तैयार हैं?

हमारे एप्लीकेशन इंजीनियर आपकी नाइट्रोजन प्रवाह आवश्यकताओं, सक्शन स्थितियों, डिस्चार्ज दबाव लक्ष्यों और एकीकरण संबंधी बाधाओं का मूल्यांकन करने के लिए तत्पर हैं। आपकी पूछताछ प्राप्त होने के 48 घंटों के भीतर हम निःशुल्क तकनीकी प्रस्ताव, फाउंडेशन लेआउट ड्राइंग, पाइपिंग और इंस्ट्रूमेंटेशन डायग्राम (P&ID) और स्वामित्व की कुल लागत (TCO) का विस्तृत विश्लेषण प्रदान करते हैं।

ईमेल: [email protected] 24 घंटों के भीतर जवाब