説明
LW-40/4 Nitrogen Compressor – Oil-Free N2 Booster for Medium-Pressure Industrial Gas Distribution
Engineered to deliver 40 m³/min at 0.40 MPa discharge pressure, the LW-40/4 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for cryogenic air separation backup, VPSA nitrogen boosting, and medium-pressure pipeline distribution networks. Zero oil contamination, continuous-duty rated, and optimized for 24/7 industrial operation.
製品概要
の LW-40/4 nitrogen compressor occupies a critical position in our oil-free piston compressor portfolio, bridging the gap between low-pressure nitrogen generation and medium-pressure distribution requirements. With a rated capacity of 40 m³/min 吐出圧力 0.40 MPa, this unit is the workhorse of medium-scale cryogenic air separation plants, VPSA nitrogen booster stations, and industrial gas pipeline networks.
What distinguishes the LW-40/4 from conventional lubricated alternatives is its 完全にオイルフリーの圧縮経路. The piston rings and rider bands are fabricated from self-lubricating PTFE composite materials that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This characteristic is indispensable for applications requiring ISO 8573-1 Class 0 certification, including food packaging nitrogen, pharmaceutical inerting, and semiconductor process gas supply.
The compressor architecture follows a 二段二列 (二列二级) layout 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 compression stage is equipped with an independent intercooler, ensuring gas temperatures remain within safe operating envelopes even under sustained maximum load conditions.
Technical Specifications – LW-40/4
| パラメータ | 価値 | ユニット |
|---|---|---|
| モデル | LW-40/4 | – |
| パターン | 二段二列 (二列二级) | – |
| 容量 | 40 | m³/分 |
| 吐出圧力 | 0.40 | MPa |
| コンプレッサーのサイズ（長さ×幅×高さ） | 3260 × 1655 × 2548 | mm |
| 重さ | 4.50 | t |
| 力 | 160 | kW |
| 電圧 | 380 | V |
| ガス媒体 | 窒素（N₂） | – |
| 潤滑 | オイルフリー | – |
* すべての仕様は標準基準条件（ISO 1217、附属書C）に基づいています。実際の性能は、設置場所の標高、周囲温度、および吸気条件によって異なる場合があります。
主な特長とエンジニアリング上の利点
1. Oil-Free PTFE Piston Ring Technology
The LW-40/4 utilizes a proprietary 自己潤滑ピストンリングおよびライダーバンドアセンブリ manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material combination achieves a coefficient of friction below 0.08 without any external lubrication, eliminating the risk of oil vapor carryover into the nitrogen product stream. For buyers operating in regulated industries, this translates directly to ISO 8573-1 クラス0準拠 without the capital and operating costs of downstream oil-filtration systems.
2. Staged Compression with Intercooling
の 2段階圧縮アーキテクチャ of the LW-40/4 is thermodynamically optimized for the 0.40 MPa discharge pressure target. By splitting 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 and preventing thermal degradation of the PTFE sealing elements. This thermal management strategy extends valve plate life by approximately 35% compared to single-stage designs operating at equivalent pressure ratios.
3. Robust Cast-Iron Frame with Force Balance
メインフレームは鋳造されています GG25 グレー鋳鉄 (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. This mechanical advantage allows the LW-40/4 to operate on a lighter foundation block (minimum 6 tonnes versus 10+ tonnes for single-row equivalents), reducing civil engineering costs and simplifying retrofit installations in existing compressor houses.
4. 標準380V産業用モータードライブ
The LW-40/4 is driven by a 160 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. The standard 380V configuration eliminates the need for medium-voltage switchgear or step-down transformers, making this model particularly attractive for facilities with existing low-voltage distribution infrastructure. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied on a common skid.
アプリケーションシナリオ
Cryogenic Air Separation Backup & Peak Shaving
In cryogenic ASU operations, the LW-40/4 serves as a reliable backup nitrogen booster or peak-shaving compressor. When the primary ASU experiences a cold box upset or requires maintenance, the LW-40/4 can maintain nitrogen supply to critical downstream consumers from liquid nitrogen storage vaporizers. Its 0.40 MPa discharge pressure is sufficient to feed medium-pressure distribution headers serving steel mill inerting, chemical reactor blanketing, and LNG plant purge gas systems. The oil-free design is particularly critical in backup scenarios where nitrogen purity cannot be compromised during primary system outages.
VPSA窒素ブースターステーション
真空圧力スイング吸着（VPSA）窒素発生装置は、大気圧に近い圧力（0.05～0.10 MPa）で気体窒素を生成する。 LW-40/4 nitrogen booster compresses this low-pressure product to 0.40 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.
Petrochemical Pipeline Nitrogen Injection
In petrochemical and refinery operations, nitrogen is injected into process pipelines and storage vessels to maintain inert atmospheres during startup, shutdown, and product changeover procedures. The LW-40/4’s 0.40 MPa discharge pressure provides adequate head to overcome pipeline friction losses over distances up to 2 km, making it suitable for centralized nitrogen supply to multiple process units. The continuous-duty rating ensures uninterrupted nitrogen availability during extended maintenance campaigns that may last several weeks.
Food & Beverage Modified Atmosphere Packaging
Large-scale food packaging facilities require high-flow nitrogen for ガス置換包装（MAP） and controlled atmosphere storage. The LW-40/4’s 40 m³/min capacity can simultaneously supply multiple high-speed packaging lines, 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.
材料と構造
Every component of the LW-40/4 is selected for compatibility with nitrogen service, corrosion resistance, and long-term mechanical integrity:
| 成分 | 材料 | 仕様 |
|---|---|---|
| シリンダーブロック | ねずみ鋳鉄 | GG25 / HT250、一体型ウォータージャケット |
| クランクシャフト | 鍛造合金鋼 | 42CrMo4、Q&T、ISO 1940 G2.5バランス |
| ピストンリング | PTFE-ガラス-青銅複合材 | 自己潤滑性、摩耗率 <0.05 mm/1000h |
| ライダーバンド | PTFE複合材 | Guide piston, prevent cylinder contact |
| バルブプレート | ステンレス鋼 | SS316, spring-loaded concentric ring design |
| コネクティングロッド | 鍛造鋼製、バビットメタルベアリング使用 | 精密加工されたオイル潤滑式ビッグエンド |
| インタークーラー | 炭素鋼製シェル／SS304製チューブ | ASME VIII Div.1、1.5倍水圧試験 |
| アフタークーラー | 炭素鋼製シェル／SS304製チューブ | フィン付きチューブ設計、冷却水温度32℃ |
All pressure vessels are designed and fabricated in accordance with ASME BPVC セクション VIII ディビジョン 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic testing (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.
設置およびメンテナンスに関するガイドライン
Foundation & Mounting
The LW-40/4 has a dry weight of 4.50 tonnes and a center of gravity approximately 850 mm above the baseplate. Due to the two-row opposed-cylinder design, the unbalanced forces are minimal, allowing installation on a 6～8トンの鉄筋コンクリート慣性ブロック. The block should be mounted on vibration isolation pads (natural frequency 6–8 Hz) to prevent vibration transmission to adjacent structures. Minimum clearance requirements: 1.5 m on the non-drive side for valve access, 1.2 m on the drive side for motor maintenance, and 2.0 m overhead for crane access during major overhauls.
Cooling Water Requirements
The LW-40/4 requires approximately 38 m³/h of cooling water at an inlet temperature not exceeding 32°C. The cooling water system must supply the cylinder jackets, intercooler, and aftercooler in parallel circuits. 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.
予防保守スケジュール
| 間隔 | サービス項目 | 対応が必要 |
|---|---|---|
| 毎日 | 運用検査 | 振動レベル、異常な騒音、冷却水流量、吐出温度を確認してください。 |
| 250時間 | Valve Inspection | 吸込弁／吐出弁のプレートを取り外し、カーボン堆積物や亀裂がないか点検する。 |
| 1,000時間 | ピストンリングの測定 | リング溝のクリアランスを測定し、クリアランスが0.25mmを超える場合はリングを交換してください。 |
| 4,000時間 | 中間オーバーホール | ピストンリング、ライダーバンド、バルブプレートアセンブリをすべて交換してください。 |
| 8,000時間 | 大規模な改修 | クランクシャフトジャーナルを点検し、ベアリングクリアランスを測定し、0.08 mmを超える場合はメインベアリングを交換する。 |
A key economic advantage of the LW-40/4 is the absence of lubricating oil in the compression path. Unlike oil-lubricated compressors that require quarterly oil changes, monthly oil analysis, and annual separator element replacement, the LW-40/4 eliminates these consumables entirely. The only recurring wear items are the PTFE piston rings and rider bands, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions.
法令遵守および安全認証
The LW-40/4 nitrogen compressor is designed, manufactured, and tested to meet the following international standards and regulatory frameworks:
ASME BPVC セクション VIII Div.1、GB 150-2011、PED 2014/68/EU モジュール A
IEC 60034-1 (IE3 efficiency), IEC 60204-1, ISO 12100 ( machinery safety)
ISO 8573-1 クラス0（油分含有量）、TÜVラインランドによる独立試験済み
ISO 9001:2015（品質マネジメント）、ISO 14001:2015（環境マネジメント）
Nitrogen is classified as a simple asphyxiant gas. All LW-40/4 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 O₂ monitors and buddy-system protocols.
パフォーマンスと効率の分析
The LW-40/4 achieves a specific power consumption of approximately 4.00 kW per m³/min of nitrogen at 0.40 MPa discharge pressure. This efficiency metric positions the unit in the upper tier of oil-free piston compressors within the 30–50 m³/min capacity range. For context, typical oil-lubricated screw compressors operating at equivalent pressure ratios consume 4.4–4.9 kW/m³/min, while legacy single-stage piston designs may exceed 5.2 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the LW-40/4’s efficiency advantage yields approximately 128,000–288,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this translates to $10,240–$23,040 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 窒素圧縮の総所有コスト is reduced by an estimated 25–35% 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-40/4’s oil-free design removes this parasitic load entirely.
カスタマイズおよびOEM対応
We offer comprehensive customization options to adapt the LW-40/4 to specific site conditions, integration requirements, and end-user specifications:
- スキッドマウント型ターンキーパッケージ： 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.
- 危険区域構成： ATEX Zone 2およびIECEx規格に準拠したモーターおよび電気機器用筐体は、爆発性雰囲気が発生する可能性のある石油化学プラントへの設置に適しています。ガス検知機能および自動換気インターロックを制御システムに組み込むことも可能です。
- 高度なプロセス制御： オプションとして、10インチHMIタッチスクリーンを備えたシーメンスS7-1200またはアレン・ブラッドリーCompactLogix PLC、Modbus TCP/IPまたはOPC-UAによるリモート監視、およびシームレスなDCS/SCADA統合が可能です。自動負荷/アンロード制御と可変速ドライブ（VFD）との互換性により、部分負荷時の効率を最適化します。
- 環境保護： 沿岸または沖合設備向けのC5-M海洋グレードコーティングシステム、周囲温度55℃までの熱帯地域向け電気部品、および1メートルで85dB(A)から72dB(A)に騒音放出を低減するIP54規格の防音筐体。
- OEMおよびプライベートブランド： システムインテグレーターおよびガス機器販売業者向けに、特注塗装色、ブランド名入り銘板、および各種資料パッケージをご用意しております。技術マニュアル、スペアパーツリスト、およびメンテナンス手順書は、現地語で提供可能です。
カスタム構成は以下から入手可能です 最小注文数量：1個技術レビューと提案書の作成には通常5～7営業日かかります。試作品の納品期間は12～14週間、リピート注文は注文確定後8～10週間で納品されます。
Case Study: VPSA Nitrogen Booster Upgrade in Southeast Asia
クライアント： A major industrial gas supplier operating a VPSA nitrogen generation facility in Vietnam
チャレンジ： The client’s existing oil-lubricated nitrogen booster (European brand, 15 years in service) was experiencing progressive oil carryover into the nitrogen product. Oil contamination levels reached 2.8 mg/m³, exceeding the 0.1 mg/m³ limit specified by their food packaging customers. The oil was also degrading the activated carbon final-polishing bed, requiring replacement every 8 months instead of the designed 24-month interval.
解決： 私たちは供給しました LW-40/4 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 2 m³ surge vessel was added upstream to dampen pressure pulsations from the VPSA adsorption cycle.
24か月後の定量的な結果：
- 窒素油含有量： Reduced from 2.8 mg/m³ to <0.01 mg/m³ISO 8573-1クラス0認証を取得
- 活性炭ベッドの交換間隔： Extended from 8 months to 30 months消耗品費を年間14兆12000円節約
- 総維持費： Decreased by 38% オイル交換、フィルター交換、セパレーターのオーバーホールが不要になったため
- エネルギー消費量： Improved by 7.2% versus the replaced unit, equivalent to $15,600/year savings at local electricity rates
- 予期せぬシステム停止： イベントゼロ 24ヶ月間の連続稼働
“The LW-40/4 eliminated our oil contamination problem completely. Our food packaging customers no longer report quality issues, and our maintenance team has cut their service time by nearly half. The payback period was under 18 months.” — Facility Operations Director
よくある質問と選択ガイド
関連製品およびソリューション
DWシリーズ高圧窒素コンプレッサー
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 range from 2 to 130 m³/min with two-stage and multi-stage configurations.
ZWシリーズ 多段式オイルフリーコンプレッサー
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, cylinder charging, and chemical process applications.
MW Series Medium-Pressure Compressors
Medium-pressure oil-free compressors (1.0–4.0 MPa) optimized for nitrogen recycle, gas liquefaction booster duty, and process gas compression in petrochemical and refinery operations.
当社の包括的な概要については、 工業用窒素圧縮機 product range, including oil-free oxygen compressors, hydrogen compressors, carbon dioxide compressors, and custom-engineered specialty gas solutions, please contact our application engineering team or browse our online product catalog.
窒素圧縮システムの最適化をお考えですか？
当社のアプリケーションエンジニアが、お客様の窒素流量要件、吸引条件、吐出圧力目標、およびシステム統合上の制約を評価するために待機しております。お問い合わせをいただいてから48時間以内に、無料の技術提案書、基礎レイアウト図、配管計装図（P&ID）、および詳細な総所有コスト（TCO）分析をご提供いたします。
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