Kompresor Nitrogen LW-20/8 – Booster N2 Bebas Oli Kapasitas Menengah untuk Operasi Industri Berkelanjutan

Dengan kapasitas 20 m³/menit pada tekanan keluaran 0,80 MPa, LW-20/8 adalah kompresor nitrogen piston bebas oli dua tahap, dua baris yang dirancang untuk pemisahan udara kriogenik skala menengah, stasiun penguat nitrogen VPSA, dan distribusi pipa industri. Tidak ada kontaminasi pelumas, beroperasi terus menerus 24/7, dan dibangun untuk lingkungan industri yang menuntut.

Gambaran Umum Produk

Itu 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 m³/min dan tekanan pelepasan sebesar 0,80 MPa, 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 jalur kompresi bebas oli sepenuhnya. 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.

Kompresor tersebut menggunakan sebuah dua tahap, dua baris (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 masa pakai minimum 15 tahun sesuai dengan protokol perawatan standar.

Technical Specifications – LW-20/8

* 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. Sistem Penyegelan Komposit PTFE Bebas Minyak

The LW-20/8 utilizes an advanced rakitan ring piston pelumas otomatis dan pita penggerak 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 Kepatuhan ISO 8573-1 Kelas 0 natively—without the capital expense, maintenance burden, or energy penalty of downstream oil-removal filtration systems.

2. Two-Stage Thermodynamic Optimization

Itu 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 Besi cor abu-abu GG25 (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. Penggerak Motor Industri Standar 380V

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.

Skenario Aplikasi

Pabrik Pemisahan Udara Kriogenik Skala Menengah

In cryogenic ASU facilities producing 500–1,500 Nm³/h of gaseous nitrogen, the LW-20/8 serves as the penguat nitrogen utama 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.

Stasiun Penguat Nitrogen VPSA

Generator nitrogen Vacuum Pressure Swing Adsorption (VPSA) menghasilkan nitrogen gas pada tekanan mendekati tekanan atmosfer (0,05–0,10 MPa). 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.

Pengolahan Makanan & Pengemasan Atmosfer Termodifikasi

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.

Bahan & Konstruksi

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

Semua komponen penahan tekanan dirancang dan dibuat sesuai dengan ASME BPVC Bagian VIII Divisi 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.

Panduan Pemasangan & Pemeliharaan

Foundation & Mounting Requirements

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 Blok inersia beton bertulang seberat 5–6 ton. 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.

Cooling Water System Specifications

Kebutuhan aliran air pendingin adalah sekitar... 22 m³/jam 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.

Jadwal Pemeliharaan Pencegahan

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 Ring piston PTFE dan sabuk penggerakyang biasanya mencapai masa pakai 4.000–6.000 jam dalam kondisi nitrogen bersih.

Sertifikasi Kepatuhan & Keselamatan

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

Analisis Kinerja & Efisiensi

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 total biaya kepemilikan untuk kompresi nitrogen dikurangi sekitar 20–30% selama masa operasional 10 tahun.

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.

Kemampuan Kustomisasi & OEM

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

• Paket Siap Pakai yang Dipasang di Atas Rangka (Skid-Mounted): 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.
• Konfigurasi Area Berbahaya: ATEX Zone 2 and IECEx compliant motor and electrical enclosures are available for installations in petrochemical facilities where explosive atmospheres may occasionally be present. Gas detection and automatic ventilation interlocks can be integrated 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. Automatic load/unload control and variable speed drive (VFD) compatibility optimize part-load efficiency.
• Perlindungan Lingkungan: 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 85 dB(A) to 72 dB(A) at 1 meter.
• OEM & Private Label: Custom paint colors, branded nameplates, and documentation packages are available for system integrators and gas equipment distributors. Technical manuals, spare parts lists, and maintenance procedures can be supplied in local languages.

Konfigurasi khusus tersedia dari MOQ 1 unit. Engineering review and proposal generation typically require 5–7 business days. Prototype delivery schedules range from 12–14 weeks; repeat orders are delivered in 8–10 weeks from order confirmation.

Case Study: Food Packaging Nitrogen Supply Upgrade

Klien: A major snack food manufacturer in Thailand

Tantangan: 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.

Larutan: Kami menyediakan sebuah 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.

Hasil Terukur Setelah 24 Bulan:

• Nitrogen supply cost: Dikurangi sebesar 48% versus liquid nitrogen purchase and delivery
• Oil contamination in nitrogen: Dihilangkan sepenuhnya (ISO 8573-1 Class 0 achieved)
• Product recall incidents: Nol since commissioning (previously 2–3 per year)
• Maintenance expenditure: Decreased by 35% karena penghapusan penggantian oli, penggantian filter, dan perbaikan separator.
• Production downtime: Dikurangi sebesar 60% (no more liquid nitrogen delivery scheduling conflicts)
• Periode pengembalian modal: 2,1 tahun 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.” — Manajer Teknik Pabrik

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