LW-6/30 Nitrogen Compressor – High-Pressure Oil-Free N2 Booster for 3.00 MPa Process Applications

Engineered to deliver 6 m³/min at 3.00 MPa discharge pressure, the LW-6/30 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, gas cylinder filling stations, and demanding chemical process applications. Zero oil contamination, robust construction, and optimized for continuous-duty operation at extreme pressure.

Gambaran Umum Produk

Itu LW-6/30 nitrogen compressor occupies a commanding position within our oil-free piston compressor family, engineered for applications where extreme discharge pressure is the defining requirement. With a rated capacity of 6 m³/menit dan luar biasa Tekanan pelepasan 3,00 MPa, this unit addresses the most demanding high-pressure nitrogen boosting requirements in industrial gas infrastructure, chemical processing, and specialty gas distribution.

What distinguishes the LW-6/30 from conventional alternatives is its jalur kompresi bebas oli sepenuhnya utilizing self-lubricating PTFE composite piston rings and rider bands. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is dramatically amplified compared to low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for applications requiring ISO 8573-1 Class 0 certification. The absence of hydrocarbon lubricants eliminates the need for downstream oil-filtration systems that would be both expensive and technically challenging to implement effectively at this pressure level.

The compressor architecture employs a two-stage, two-row (二列二级) configuration that is thermodynamically essential for managing the extreme pressure ratio required to achieve 3.00 MPa from typical inlet conditions. Each stage is independently cooled through a high-efficiency intercooler, ensuring gas temperatures remain within safe operating envelopes and preserving the dimensional stability of the PTFE sealing elements. The reinforced cast-iron frame and dynamically balanced forged steel crankshaft are engineered for a minimum service life of 120,000 hours under standard maintenance protocols.

Technical Specifications – LW-6/30

* Semua spesifikasi dinilai pada kondisi referensi standar (ISO 1217, Lampiran C). Kinerja aktual dapat bervariasi berdasarkan ketinggian lokasi, suhu lingkungan, dan kondisi saluran masuk.

Fitur Utama & Keunggulan Teknik

1. Extreme-Pressure Oil-Free PTFE Sealing System

The LW-6/30 employs a proprietary rakitan ring piston pelumas otomatis dan pita penggerak manufactured from high-density PTFE composites specifically formulated for extreme-pressure service. These rings are reinforced with glass fiber and bronze particulates to achieve a coefficient of friction below 0.06 without any external hydrocarbon lubrication. At 3.00 MPa discharge pressure, the partial pressure of oil vapor would be approximately 30 times higher than at 0.30 MPa, making conventional oil-lubricated designs completely unsuitable for high-purity applications. The PTFE composite formulation is rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity under the intense thermal stress of 3.00 MPa compression. For operators in pharmaceutical, semiconductor, and food-grade nitrogen production, this native oil-free design delivers ISO 8573-1 Class 0 compliance without any downstream purification equipment.

2. Two-Stage Compression for Extreme Pressure Ratios

Itu two-stage compression architecture of the LW-6/30 is thermodynamically mandatory for achieving the 3.00 MPa discharge pressure target from typical inlet pressures of 0.05–0.10 MPa. The overall pressure ratio of approximately 30:1 to 60:1 is split between a low-pressure cylinder and a high-pressure cylinder, with each stage operating at a manageable pressure ratio. A high-efficiency shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 160°C and preventing thermal degradation of the PTFE sealing elements. Without staged compression, the discharge temperature would exceed 250°C—far beyond the safe operating limit of any oil-free sealing material. The two-stage design also improves volumetric efficiency by reducing the re-expansion losses that would occur in a single-stage compressor operating at such extreme pressure ratios.

3. Reinforced Frame for High-Pressure Mechanical Loads

Kerangka utama dicetak dari Besi cor abu-abu GG25 with reinforced wall sections, additional ribbing, and integral cooling water passages. The high-pressure cylinder features substantially thicker walls and enhanced structural support to withstand the peak gas forces associated with 3.00 MPa operation. The two-row opposed-cylinder arrangement provides natural first-order force cancellation, which is particularly critical for high-pressure compressors where the peak forces on the pistons can be three to four times greater than in low-pressure equivalents. This mechanical advantage reduces vibration transmission to the foundation and extends the service life of bearings, connecting rods, and crankshaft journals.

4. Penggerak Motor Industri Standar 380V

The LW-6/30 is driven by a 65 kW, 380V, 50Hz three-phase induction motor 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 switchgear or step-down transformers. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the unit accessible to a wide range of industrial facilities. The 65 kW power rating is optimized for the 6 m³/min capacity at 3.00 MPa, delivering a specific power consumption that is competitive within the high-pressure oil-free compressor segment.

Skenario Aplikasi

High-Pressure Nitrogen Cylinder Filling Stations

The LW-6/30 is ideally suited for nitrogen cylinder filling operations where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa filling pressure. While the compressor’s 3.00 MPa discharge pressure does not reach cylinder filling pressure directly, it serves as a highly efficient intermediate booster that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. This staged approach improves overall system efficiency by 15–25% and reduces wear on the expensive high-pressure filling equipment. The 6 m³/min capacity can support cylinder filling rates of 80–120 cylinders per hour, making it suitable for commercial gas filling stations serving industrial, medical, and specialty gas customers. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users.

Chemical Process High-Pressure Nitrogen Injection

Di pabrik pengolahan kimia, LW-6/30 high-pressure nitrogen compressor provides nitrogen for high-pressure reactor inerting, catalyst bed preservation, and emergency nitrogen injection into process vessels operating at elevated pressures. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 2.4 MPa, maintaining positive inert gas blankets during startup, shutdown, and upset conditions. The oil-free certification is essential for chemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely free of hydrocarbon contamination. Even trace oil contamination can poison precious metal catalysts, degrade polymerization reactions, or cause off-specification product batches.

Gas Liquefaction & Cryogenic Storage Pressure Boosting

In nitrogen liquefaction plants and cryogenic storage facilities, the LW-6/30 compresses nitrogen to the high pressure required for liquefaction cycle feed, cryogenic storage tank pressurization, and liquid nitrogen transfer pumping. The 3.00 MPa discharge pressure is suitable for driving nitrogen through the heat exchangers and expansion turbines of small to medium-scale liquefaction plants. The oil-free design prevents oil contamination of the cryogenic equipment, where even microscopic oil residues can freeze and block narrow passages in heat exchangers and expansion valves, causing catastrophic process upsets.

Pipeline Pressure Testing & Hydrostatic Testing

The oil and gas industry, chemical plants, and power generation facilities require high-pressure nitrogen for pipeline pressure testing, hydrostatic testing of pressure vessels, and pneumatic testing of process equipment. The LW-6/30’s 3.00 MPa discharge pressure is suitable for testing pipelines and vessels rated up to 2.4 MPa design pressure (per ASME B31.3, test pressure = 1.5× design pressure). Nitrogen is preferred over water for testing in cold climates (preventing freezing), in systems that must remain dry (electrical equipment, gas pipelines), and in applications where water contamination would be difficult to remove. The oil-free design ensures that the test medium itself does not introduce contamination into the tested system.

Bahan & Konstruksi

The LW-6/30 is constructed from premium materials selected for extreme-pressure nitrogen compatibility, thermal resistance, and extended operational life:

Semua komponen penahan tekanan dirancang dan dibuat sesuai dengan standar yang ketat. ASME BPVC Bagian VIII Divisi 1 atau standar GB 150 Tiongkok. Setiap sambungan las menjalani inspeksi radiografi (RT) 100% sesuai dengan ASME Bagian V, Pasal 2, dan setiap bejana tekan yang telah selesai diuji tekanan hidrostatik pada 1,5 kali tekanan kerja maksimum yang diizinkan (MAWP) untuk periode penahanan minimum 30 menit. Sistem perpipaan bertekanan tinggi dibuat dari SS316 tanpa sambungan dengan sambungan flensa ANSI Kelas 900 untuk memastikan integritas kedap bocor pada tekanan operasi 3,00 MPa.

Panduan Pemasangan & Pemeliharaan

Persyaratan Pondasi & Struktur

The LW-6/30 has a dry weight of 2.70 tonnes and a center of gravity approximately 800 mm above the baseplate. Due to the two-row opposed-cylinder design, unbalanced forces are minimal despite the extreme pressure operation, permitting installation on a Blok inersia beton bertulang seberat 5–6 ton. The block should be mounted on elastomeric vibration isolators (natural frequency 7–10 Hz). 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 1.5 m overhead for crane access. Special attention must be paid to the high-pressure discharge piping, which must be properly supported, anchored, and stress-relieved to prevent vibration-induced fatigue at 3.00 MPa. All high-pressure piping must be designed in accordance with ASME B31.3 Process Piping standards.

Desain Sistem Air Pendingin

Kebutuhan air pendingin kira-kira 15 m³/jam at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and intercooler in parallel. Given the extreme pressure ratio, the intercooler is absolutely critical for thermal management and must receive priority cooling water flow at all times. 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 to prevent scale formation and corrosion in the high-pressure heat exchangers.

Jadwal Pemeliharaan Pencegahan

The oil-free design of the LW-6/30 dramatically simplifies maintenance 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 Ring piston PTFE dan sabuk penggerak, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. The extreme-pressure valve plates may require more frequent inspection than low-pressure equivalents due to the substantially increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

Sertifikasi Kepatuhan & Keselamatan

The LW-6/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Analisis Kinerja & Efisiensi

The LW-6/30 achieves a specific power consumption of approximately 10.83 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of extreme-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 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 extreme-pressure applications typically consume 11.5–13.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the LW-6/30’s efficiency advantage versus less efficient alternatives yields approximately 48,000–96,000 kWh of annual energy savings. At $0.08/kWh, this represents $3,840–$7,680 in direct electricity cost reduction per year. However, the primary economic driver for LW-6/30 selection is typically the penghapusan bahan habis pakai terkait minyak dan penghindaran peralatan penghilang minyak hilir that would be mandatory with lubricated alternatives. At 3.00 MPa, the partial pressure of oil vapor is approximately 30 times higher than at 0.30 MPa, making downstream oil-filtration systems both less effective and more expensive. The total cost of ownership for extreme high-pressure nitrogen compression Diperkirakan berkurang sebesar 30–45% selama masa operasional 10 tahun jika pengoperasian tanpa oli dibandingkan dengan sistem yang dilumasi dengan pemurnian hilir penuh.

The absence of oil in the compression path is particularly critical at 3.00 MPa because oil contamination becomes progressively more concentrated and more difficult to remove as pressure increases. At this pressure level, even sub-ppm oil contamination can cause significant problems in downstream process equipment, catalyst beds, and cryogenic systems. The LW-6/30’s native oil-free design eliminates this challenge entirely, delivering consistent ISO 8573-1 Class 0 nitrogen regardless of operating pressure.

Kemampuan Kustomisasi & OEM

We offer comprehensive customization options to adapt the LW-6/30 to specific site conditions, integration requirements, and end-user specifications:

• Paket Siap Pakai yang Dipasang di Atas Rangka (Skid-Mounted): Pre-assembled compressor, motor, intercooler, aftercooler, high-pressure discharge piping, instrumentation, and control panel on a structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces field commissioning time and risks.
• Konfigurasi Area Berbahaya: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks incorporated into the control system.
• Kontrol Proses Tingkat Lanjut: 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 DCS/SCADA integration. High-pressure safety interlocks including automatic unload on overpressure, emergency isolation valves, and redundant pressure monitoring.
• Perlindungan Lingkungan: 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 85 dB(A) to 72 dB(A) at 1 meter.
• OEM & Private Label: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators. Technical manuals, spare parts lists, and maintenance procedures in multiple languages.

Konfigurasi khusus tersedia dari MOQ 1 unitTinjauan teknik dan pembuatan proposal biasanya membutuhkan waktu 5–7 hari kerja. Waktu pengiriman standar adalah 12–14 minggu; pesanan berulang dikirim dalam waktu 8–10 minggu sejak konfirmasi pesanan.

Case Study: Chemical Plant High-Pressure Nitrogen System Upgrade

Klien: A specialty chemical manufacturer in Malaysia operating high-pressure polymerization reactors

Tantangan: The plant was using an oil-lubricated high-pressure compressor to supply nitrogen for reactor inerting and catalyst bed preservation at 2.50 MPa. Oil contamination levels in the nitrogen reached 2.2 mg/m³, causing frequent catalyst poisoning incidents that required reactor shutdowns and catalyst replacement at a cost of $45,000 per incident. The oil was also depositing on reactor internals, reducing heat transfer efficiency and increasing cleaning downtime. The plant averaged 4 catalyst poisoning incidents per year, with total losses exceeding $180,000 annually.

Larutan: We supplied an LW-6/30 oil-free nitrogen compressor as the primary high-pressure booster, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel with redundant pressure monitoring and automatic emergency isolation. The 3.00 MPa discharge pressure provided a safety margin above the 2.50 MPa process requirement, ensuring reliable nitrogen delivery even during demand peaks. The oil-free design eliminated the root cause of catalyst poisoning.

Quantified Results After 24 Months:

• Kandungan nitrogen dalam minyak: Reduced from 2.2 mg/m³ to <0.01 mg/m³, mencapai ISO 8573-1 Kelas 0
• Catalyst poisoning incidents: Zero in 24 months, versus 8 incidents in the previous 24 months
• Catalyst replacement costs: Eliminated, saving $180,000/year
• Reactor cleaning downtime: Reduced by 60% due to elimination of oil deposits on internals
• Overall plant availability: Increased by 4.2%, equivalent to $320,000/year in additional production
• Periode pengembalian modal: 1.2 years based on avoided catalyst replacement costs alone

“The LW-6/30 has been the single most impactful equipment upgrade in our plant’s history. The elimination of catalyst poisoning has saved us $180,000 per year in direct costs and increased our production capacity by over 4%. The payback was achieved in just over a year. We wish we had made this change a decade ago.” — Plant Director, Specialty Chemical Manufacturing

FAQ & Panduan Seleksi

Produk & Solusi Terkait

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