Descrizione
Compressore di azoto LW-10/8 – Booster di N2 senza olio di fascia media per reti di distribuzione industriali
Delivering 10 m³/min at 0.80 MPa discharge pressure, the LW-10/8 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, continuous-duty rated, and built for reliable 24/7 operation in demanding industrial environments.
Panoramica del prodotto
IL LW-10/8 nitrogen compressor occupies a strategic position in our oil-free piston compressor lineup, bridging the gap between compact entry-level units and high-capacity industrial models. With a rated capacity of 10 m³/min and a discharge pressure of 0.80 MPa, this unit serves as the backbone of medium-scale nitrogen distribution systems in cryogenic air separation plants, VPSA booster stations, and industrial gas pipeline networks.
What sets the LW-10/8 apart from conventional lubricated alternatives is its fully oil-free compression path. The piston rings and rider bands are manufactured from self-lubricating PTFE composite materials that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This characteristic is essential for applications requiring ISO 8573-1 Class 0 certification, including food packaging nitrogen, pharmaceutical inerting, electronics manufacturing, and chemical process blanketing.
Il compressore utilizza un due stadi, due file (二列二级) configuration that divides the total pressure ratio across two compression cylinders. This staged approach reduces the discharge temperature per stage, improves volumetric efficiency, and extends the service life of valves and piston rings. Each stage is equipped with an independent intercooler, ensuring gas temperatures remain within safe operating limits even during sustained maximum load operation. The robust cast-iron frame and precision-machined crankshaft assembly are rated for over 100,000 hours of service life under standard maintenance protocols.
Technical Specifications – LW-10/8
| Parametro | Valore | Unità |
|---|---|---|
| Modello | LW-10/8 | – |
| Modello | Due stadi, due file (二列二级) | – |
| Capacità | 10 | m³/min |
| Pressione di scarico | 0.80 | MPa |
| Dimensioni del compressore (L × P × A) | 2340 × 910 × 2070 | mm |
| Peso | 1.80 | T |
| Energia | 65 | kW |
| Voltaggio | 380 | V |
| Gas medio | Azoto (N₂) | – |
| Lubrificazione | Senza olio | – |
* Tutte le specifiche sono valutate in condizioni di riferimento standard (ISO 1217, Allegato C). Le prestazioni effettive possono variare in base all'altitudine del sito, alla temperatura ambiente e alle condizioni di ingresso.
Caratteristiche principali e vantaggi ingegneristici
1. Oil-Free PTFE Composite Sealing System
The LW-10/8 utilizes a proprietary Gruppo di fasce elastiche e anelli di scorrimento autolubrificanti manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material 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 operators in regulated industries, this translates directly to ISO 8573-1 Class 0 compliance without the capital expense and ongoing maintenance burden of downstream oil-filtration equipment such as coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation.
2. Two-Stage Thermodynamic Optimization
IL architettura di compressione a due stadi of the LW-10/8 is thermodynamically optimized for the 0.80 MPa discharge pressure target. By dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor achieves a lower mean effective temperature per stage. A dedicated shell-and-tube intercooler between stages removes the heat of compression, maintaining discharge temperatures below 155°C even at maximum continuous load. This thermal management strategy extends valve plate life by approximately 35% compared to single-stage designs operating at equivalent overall pressure ratios, and it prevents thermal degradation of the PTFE sealing elements that could otherwise compromise oil-free performance.
3. Compact Yet Robust Frame Construction
La struttura principale è realizzata in fusione Ghisa grigia GG25 (equivalent to ASTM A48 Class 30B) with integral cooling water passages. The two-row opposed-cylinder arrangement provides natural first-order force cancellation, reducing the unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs. At just 1.80 tonnes, the LW-10/8 can be installed using standard forklift equipment, yet its robust construction is rated for over 100,000 hours of service life. The compact dimensions—2340 × 910 × 2070 mm—make it suitable for installations where floor space is limited, such as retrofit projects in existing compressor houses or containerized nitrogen supply systems.
4. Standard 380V Industrial Motor Drive
The LW-10/8 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 infrastructure, step-down transformers, or specialized switchgear. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the LW-10/8 an attractive option for facilities upgrading from liquid nitrogen vaporization or bottled gas to on-site compression. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied on a common skid.
Scenari applicativi
Medium-Scale Cryogenic Air Separation Plants
In cryogenic ASU (Air Separation Unit) facilities producing 500–1,500 Nm³/h of gaseous nitrogen, the LW-10/8 serves as the primary nitrogen booster between the cold box and the gaseous nitrogen distribution header. Its 10 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 reactor blanketing systems, steel mill inerting stations, and LNG plant purge gas networks. The oil-free design is particularly critical in ASU service because any hydrocarbon contamination would degrade the cryogenic separation efficiency and potentially damage downstream molecular sieve dryers.
VPSA Nitrogen Booster Stations
Vacuum Pressure Swing Adsorption (VPSA) nitrogen generators produce gaseous nitrogen at near-atmospheric pressure (0.05–0.10 MPa). The LW-10/8 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 nitrogen generator’s separation efficiency and requiring costly adsorbent replacement that can exceed $50,000 for a medium-scale unit. The LW-10/8’s native oil-free certification protects this critical investment.
Chemical Process Blanketing & Inerting
Chemical manufacturing facilities require large volumes of nitrogen for reactor blanketing, vessel inerting, and pipeline purging to prevent explosive vapor formation and oxidative degradation of sensitive products. The LW-10/8’s 0.80 MPa discharge pressure provides adequate head to overcome pressure relief valve settings and maintain positive pressure in multiple reactors and storage vessels simultaneously. The continuous-duty rating ensures uninterrupted nitrogen availability during extended production campaigns that may run for months without shutdown. The oil-free design is mandatory in chemical applications where even trace oil contamination could catalyze unwanted side reactions or contaminate high-purity product streams.
Food Packaging & Modified Atmosphere Storage
Medium-scale food packaging facilities require a steady supply of high-purity nitrogen for modified atmosphere packaging (MAP), controlled atmosphere storage, and nitrogen flushing of packaging lines. The LW-10/8’s 10 m³/min capacity can simultaneously supply multiple high-speed packaging machines, while its oil-free certification ensures compliance with FDA 21 CFR 173.310 (food-grade nitrogen) and EU Regulation 231/2012. The absence of oil contamination eliminates the risk of off-flavors, rancidity, or product discoloration that can occur when lubricated compressors are used in food-contact applications, protecting brand reputation and consumer safety.
Materiali e costruzione
Every component of the LW-10/8 is selected for compatibility with nitrogen service, corrosion resistance, and long-term mechanical integrity:
| Componente | Materiale | Specifiche |
|---|---|---|
| Cylinder Block | Ghisa grigia | GG25 / HT250, integral water jackets |
| Albero motore | acciaio legato forgiato | 42CrMo4, Q&T, ISO 1940 G2.5 bilanciato |
| Fasce elastiche del pistone | Composito PTFE-vetro-bronzo | Self-lubricating, wear rate <0.05 mm/1000h |
| Fasce dei cavalieri | Composito in PTFE | Piston guidance, prevent cylinder scoring |
| Piastre delle valvole | acciaio inossidabile | SS316, concentric ring spring-loaded design |
| Connecting Rods | Forged Steel with Babbitt Bearings | Precision-machined, oil-lubricated big end |
| Intercooler | Carbon Steel Shell / SS304 Tubes | ASME VIII Div.1, 1.5× hydrotest |
| Postrefrigeratore | Carbon Steel Shell / SS304 Tubes | Finned tube design, 32°C cooling water |
All pressure-bearing components are designed and fabricated in accordance with ASME BPVC Sezione VIII Divisione 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2, and each completed 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.
Linee guida per l'installazione e la manutenzione
Foundation & Mounting Requirements
The LW-10/8 weighs 1.80 tonnes and features a low center of gravity due to its compact design. A reinforced concrete inertia block of 4–5 tonnes is recommended, mounted on elastomeric vibration isolators (natural frequency 6–8 Hz). The two-row opposed-cylinder arrangement inherently cancels first-order inertial forces, minimizing vibration transmission to adjacent structures. Required clearances: 1.2 m on the non-drive side for valve maintenance, 1.0 m on the drive side for motor access, and 1.8 m overhead for crane access during major overhauls. The compact footprint allows installation in existing machinery rooms without structural modifications.
Cooling Water System Specifications
La richiesta di acqua di raffreddamento è approssimativamente 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets, intercooler, and aftercooler in parallel. Acceptable water quality: 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 maintain heat transfer efficiency.
Programma di manutenzione preventiva
| Intervallo | Articolo di servizio | Azione richiesta |
|---|---|---|
| Quotidiano | Ispezione operativa | Check vibration levels, abnormal noise, cooling water flow, discharge temperature |
| 250 ore | Ispezione della piastra delle valvole | Remove and inspect suction/discharge valve plates for carbon deposits or cracking |
| 1.000 ore | Piston Ring Measurement | Measure ring groove clearance; replace rings if clearance exceeds 0.25 mm |
| 4,000 hours | Revisione intermedia | Sostituire tutte le fasce elastiche del pistone, le fasce di scorrimento e i gruppi della piastra delle valvole. |
| 8,000 hours | Revisione completa | Inspect crankshaft journals, measure bearing clearances, replace main bearings if >0.08 mm |
The oil-free design of the LW-10/8 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 oil separator cartridges to monitor. The only consumable wear items are the Fasce elastiche e anelli di scorrimento in PTFE, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions. This maintenance simplicity translates to lower labor costs, reduced spare parts inventory, and higher equipment availability.
Certificazioni di conformità e sicurezza
The LW-10/8 nitrogen compressor meets or exceeds the following international standards and regulatory requirements:
ASME BPVC Sezione VIII Div.1, GB 150-2011, PED 2014/68/UE Modulo A
IEC 60034-1 (IE3 efficiency), IEC 60204-1, ISO 12100 (machinery safety)
ISO 8573-1 Classe 0 (Contenuto di olio), testato in modo indipendente da TÜV Rheinland
ISO 9001:2015 (Gestione della Qualità), ISO 14001:2015 (Gestione Ambientale)
⚠️ Critical Safety Advisory
Nitrogen is an odorless, colorless asphyxiant gas. All LW-10/8 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and adjacent areas. Ventilation systems must be designed to maintain ambient oxygen concentrations above 19.5% volume per OSHA 29 CFR 1910.146 (Permit-Required Confined Spaces). Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic compressor isolation at 18.0% O₂ (hard shutdown). Personnel entry procedures must include portable oxygen monitors and a buddy system protocol.
Analisi delle prestazioni e dell'efficienza
The LW-10/8 achieves a specific power consumption of approximately 6.50 kW per m³/min of nitrogen delivered at 0.80 MPa discharge pressure. This efficiency metric positions the unit competitively within the 8–15 m³/min oil-free piston compressor segment. For comparison, oil-lubricated screw compressors in similar applications typically consume 7.0–7.8 kW/m³/min, while legacy single-stage piston designs may exceed 8.5 kW/m³/min.
Over a standard 8,000-hour annual operating cycle, the LW-10/8’s efficiency advantage yields approximately 40,000–104,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $3,200–$8,320 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 cost of ownership for nitrogen compression is reduced by an estimated 20–30% 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 requires coalescing filters, activated carbon adsorbers, and monitoring instrumentation that collectively consume 3–5% of the compressor’s power output. The LW-10/8’s oil-free design removes this parasitic load entirely, further improving the effective system efficiency.
Capacità di personalizzazione e produzione OEM
We offer comprehensive customization options to adapt the LW-10/8 to specific site conditions, integration requirements, and end-user specifications:
- Pacchetti chiavi in mano con montaggio su skid: Pre-assembled compressor, motor, intercooler, aftercooler, instrumentation, and control panel 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.
- Configurazioni delle aree pericolose: 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.
- Controllo avanzato dei processi: 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.
- Protezione ambientale: 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 e 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.
Le configurazioni personalizzate sono disponibili da Quantità minima d'ordine: 1 unità. 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: Chemical Plant Nitrogen Distribution Upgrade
Cliente: A specialty chemical manufacturer in Thailand
Sfida: The client’s existing oil-lubricated nitrogen booster (Japanese brand, 10 years in service) was experiencing progressive oil carryover into the nitrogen distribution network. Oil contamination levels reached 1.5 mg/m³, causing product quality issues in their high-purity chemical synthesis processes and triggering customer complaints. The oil was also fouling the activated carbon final-polishing bed, requiring replacement every 6 months at a cost of $8,000 per change.
Soluzione: Abbiamo fornito un LW-10/8 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel. The skid footprint was engineered to match the existing foundation, eliminating the need for civil modifications. A 1.5 m³ surge vessel was added upstream to dampen pressure pulsations from the VPSA adsorption cycle.
Quantified Results After 24 Months:
- Nitrogen oil content: Ridotto da 1,5 mg/m³ a <0,01 mg/m³, achieving ISO 8573-1 Class 0 certification
- Activated carbon bed replacement interval: Extended from 6 months to 24 months, saving $12,000/year in consumables
- Overall maintenance expenditure: Decreased by 35% due to elimination of oil changes, filter replacements, and separator overhauls
- Energy consumption: Improved by 6.8% versus the replaced unit, equivalent to $4,800/year savings at local electricity rates
- Unplanned downtime: Zero events in 24 months of continuous operation
“The LW-10/8 completely eliminated our oil contamination issues. Our chemical synthesis product quality has improved significantly, and our maintenance team spends far less time on compressor service. The payback period was just over 2 years.” — Plant Engineering Manager
Domande frequenti e guida alla selezione
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For a complete overview of our compressore industriale di azoto Per maggiori informazioni sulla nostra gamma di prodotti, che comprende compressori di ossigeno senza olio, compressori di idrogeno, compressori di anidride carbonica e soluzioni personalizzate per gas speciali, contattate il nostro team di ingegneri applicativi o consultate il nostro catalogo prodotti online.
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