説明
LW-5.3/16 窒素コンプレッサー – 過酷な産業用途向け高圧オイルフリーN2ブースター
Engineered to deliver 5.3 m³/min at 1.60 MPa discharge pressure, the LW-5.3/16 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, gas cylinder filling, and specialized petrochemical inerting operations. Zero oil contamination, compact footprint, and optimized for medium-duty industrial service at elevated pressure.
製品概要
の LW-5.3/16 nitrogen compressor occupies a specialized niche within our oil-free piston compressor portfolio, engineered for applications that demand both moderate flow capacity and significantly elevated discharge pressure. With a rated capacity of 5.3 m³/min and an impressive 1.60 MPa discharge pressure, this unit bridges the gap between conventional low-pressure nitrogen boosters and ultra-high-pressure gas filling systems.
What distinguishes the LW-5.3/16 is its completely oil-free compression mechanism utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, making the unit immediately suitable for high-purity nitrogen cylinder filling, pharmaceutical-grade inerting, and electronics manufacturing where even trace oil content would compromise product integrity. The native oil-free certification achieves ISO 8573-1 クラス0準拠 without requiring additional downstream purification equipment.
Its 二段二列 (二列二级) configuration is thermodynamically optimized for the high pressure ratio required to reach 1.60 MPa. The staged compression approach divides the total pressure burden between a low-pressure cylinder and a high-pressure cylinder, with an inter-stage cooler removing the heat of compression to maintain gas temperatures within safe limits. This thermal management is critical for preserving the integrity of the PTFE sealing elements under the demanding conditions of high-pressure operation. The compact dimensions—1947 × 1900 × 2580 mm—and manageable weight of 3.97 tonnes make the LW-5.3/16 suitable for installations where space is at a premium.
Technical Specifications – LW-5.3/16
| パラメータ | 価値 | ユニット |
|---|---|---|
| モデル | LW-5.3/16 | – |
| パターン | 二段二列 (二列二级) | – |
| 容量 | 5.3 | m³/分 |
| 吐出圧力 | 1.60 | MPa |
| コンプレッサーのサイズ（長さ×幅×高さ） | 1947 × 1900 × 2580 | mm |
| 重さ | 3.97 | t |
| 力 | 55 | 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. High-Pressure Oil-Free PTFE Sealing Technology
The LW-5.3/16 employs a specialized 自己潤滑ピストンリングおよびライダーバンドシステム manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. This material formulation is specifically engineered for high-pressure service, achieving a coefficient of friction below 0.08 without any external hydrocarbon lubrication. The rings are dimensionally stable at temperatures up to 180°C, which is essential for managing the thermal loads associated with 1.60 MPa discharge pressure. For operators requiring high-purity nitrogen, this design delivers native ISO 8573-1 Class 0 compliance, eliminating the need for costly downstream oil-filtration systems.
2. Two-Stage Compression for Extreme Pressure Ratios
の 2段階圧縮アーキテクチャ is indispensable for achieving the 1.60 MPa discharge pressure from typical inlet conditions of 0.05–0.10 MPa. By dividing the overall pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the LW-5.3/16 maintains manageable discharge temperatures per stage. A dedicated high-efficiency shell-and-tube intercooler between stages removes the heat of compression, keeping gas temperatures below 160°C even at maximum continuous load. This thermal management strategy is critical for preserving PTFE ring integrity under high-pressure conditions and extends valve plate service life by approximately 35% compared to single-stage designs attempting equivalent pressure ratios.
3. Compact Design with Robust Construction
Despite its high-pressure capability, the LW-5.3/16 maintains a remarkably compact footprint of 1947 × 1900 × 2580 mm. This dimensional efficiency is achieved through a vertically oriented crankcase design that minimizes longitudinal space requirements while providing adequate maintenance access. The main frame is cast from GG25 グレー鋳鉄 with integral cooling water passages, and the two-row opposed-cylinder arrangement provides natural first-order force cancellation. At 3.97 tonnes, the unit can be transported and positioned using standard forklift equipment, eliminating the need for specialized rigging during installation or relocation.
4. Standard 380V Direct-On-Line Motor Drive
The LW-5.3/16 is powered by a 55kW、380V、50Hzの三相誘導電動機 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 or step-down transformers. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the LW-5.3/16 an attractive option for facilities upgrading from high-pressure bottled nitrogen or membrane separation systems to on-site compression.
アプリケーションシナリオ
High-Pressure Nitrogen Cylinder Filling Stations
The LW-5.3/16 is ideally suited for nitrogen cylinder filling operations where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa. The 1.60 MPa discharge pressure serves as the primary booster stage, feeding a downstream high-pressure compressor or booster pump that achieves the final cylinder charging pressure. The oil-free design is mandatory in cylinder filling applications because any oil contamination would compromise the purity of nitrogen delivered to end-users in food processing, medical, and electronics industries. The 5.3 m³/min capacity supports filling rates of 20–30 cylinders per hour, making it suitable for medium-scale filling stations serving regional industrial gas markets.
Specialized Petrochemical High-Pressure Inerting
In petrochemical operations involving high-pressure reactors, catalyst regeneration systems, and hydrocracking units, nitrogen is required at elevated pressures for reactor inerting, catalyst preservation, and emergency depressurization. The LW-5.3/16 high-pressure nitrogen compressor delivers the 1.60 MPa pressure necessary to overcome reactor operating pressures and maintain positive inert gas flow. The oil-free certification is critical in these applications because any hydrocarbon contamination would poison precious metal catalysts, degrade product quality, and create safety hazards in hydrogen-rich process environments.
Pharmaceutical High-Pressure Inerting & Blanketing
Pharmaceutical manufacturing facilities require high-purity nitrogen at elevated pressures for reactor blanketing, powder conveying, and sterile packaging operations. The LW-5.3/16’s 1.60 MPa discharge pressure is sufficient to drive pneumatic conveying systems that transport active pharmaceutical ingredients (APIs) between process vessels without contamination risk. The oil-free design ensures compliance with FDA 21 CFR 211.72 (equipment cleaning and maintenance) and EU GMP Annex 1 (manufacture of sterile medicinal products), where any oil contamination would render batches unfit for human use.
Electronics High-Pressure Process Gas Supply
Semiconductor fabrication facilities and electronics assembly plants require high-pressure nitrogen for wafer handling, chemical vapor deposition (CVD) chamber purging, and lead-free soldering operations. The LW-5.3/16’s 1.60 MPa pressure supports the high-flow pneumatic actuators and process gas manifolds used in advanced packaging lines. The oil-free certification is non-negotiable in electronics applications because even trace oil contamination can cause solder joint defects, delamination of conformal coatings, and catastrophic failure of sensitive optical components.
材料と構造
The LW-5.3/16 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal stability, and extended service life:
| 成分 | 材料 | 仕様 |
|---|---|---|
| シリンダーブロック | ねずみ鋳鉄 | GG25 / HT250, integral cooling water jackets |
| クランクシャフト | 鍛造合金鋼 | 42CrMo4, Q&T, ISO 1940 G2.5 dynamically balanced |
| ピストンリング | PTFE-ガラス-青銅複合材 | Self-lubricating, high-temp rated to 180°C |
| ライダーバンド | PTFE複合材 | Piston guidance, anti-scuffing, wear rate <0.05 mm/1000h |
| バルブプレート | ステンレス鋼 | SS316、同心円状のバネ式設計 |
| 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／SS316製チューブ | ASME VIII Div.1、1.5倍の耐圧試験、30分間保持 |
| High-Pressure Cylinder Head | Forged Steel | Normalized, 100% UT inspected |
すべての圧力支持部品は、以下の基準に従って設計および製造されています。 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 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 period 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 & Spatial Requirements
The LW-5.3/16 has a dry weight of 3.97 tonnes and a low center of gravity due to its compact vertical design. A reinforced concrete pad of 5–6 tonnes is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The two-row opposed-cylinder arrangement inherently cancels first-order inertial forces, minimizing vibration transmission. Required clearances: 1.0 m on the non-drive side for valve maintenance, 0.8 m on the drive side for motor access, and 1.5 m overhead for routine service.
Cooling Water Specifications
冷却水の需要は約 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Acceptable water quality: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride < 50 mg/L, suspended solids < 30 mg/L. For installations without reliable municipal water supply, a compact closed-loop cooling tower with a 0.5 m³ buffer tank is 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 | Visual & Operational Check | Inspect for leaks, abnormal noise, cooling water flow, discharge temperature |
| 250時間 | バルブプレートの点検 | Check for carbon deposits, spring fatigue, or plate cracking |
| 1,000時間 | ピストンリング摩耗評価 | Measure groove clearance; replace rings if clearance exceeds 0.20 mm |
| 4,000時間 | Intermediate Service | Replace piston rings, rider bands, and valve assemblies |
| 8,000時間 | 大規模な改修 | Inspect crankshaft, measure bearing clearances, replace as needed |
The oil-free design of the LW-5.3/16 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 separator cartridges to monitor. The only consumable wear items are the PTFE製ピストンリングおよびライダーバンド, 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-5.3/16 nitrogen compressor meets the following international standards and regulatory requirements:
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
ISO 8573-1 Class 0 (Oil Content), TÜV Rheinland tested
ISO 9001:2015、ISO 14001:2015
Nitrogen is an odorless, colorless asphyxiant gas. All LW-5.3/16 installations must include continuous oxygen monitoring in the compressor room and adjacent areas. Ventilation must maintain ambient oxygen above 19.5% per OSHA 29 CFR 1910.146. Alarm interlocks should trigger at 19.5% O₂ and hard shutdown at 18.0% O₂. Personnel entry requires portable oxygen monitors and a buddy system. High-pressure nitrogen systems require additional precautions including pressure relief devices, burst disc protection, and personnel training on high-pressure gas safety.
パフォーマンスと効率の分析
The LW-5.3/16 achieves a specific power consumption of approximately 10.38 kW per m³/min of nitrogen delivered at 1.60 MPa discharge pressure. While this specific power is higher than low-pressure models due to the extreme pressure ratio, it remains competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated alternatives in this pressure class typically consume 11.0–12.5 kW/m³/min, and diaphragm compressors (often selected for oil-free high-pressure service) can exceed 14 kW/m³/min.
Over an 8,000-hour annual operating cycle, the LW-5.3/16’s efficiency advantage versus less efficient alternatives yields approximately 25,000–55,000 kWh of energy savings per year. At $0.08/kWh, this represents $2,000–$4,400 in annual electricity cost reduction. However, the primary economic driver for LW-5.3/16 selection is typically the elimination of oil-related consumables and downstream purification equipment rather than marginal energy savings.
の total cost of ownership for high-pressure nitrogen compression is dominated by maintenance labor and consumables. The LW-5.3/16’s oil-free design eliminates oil changes ($300–600/year), filter replacements ($150–300/year), separator cartridge changes ($400–800/year), and oil analysis ($100–200/year), delivering total consumable savings of $950–$1,900 annually compared to lubricated alternatives.
カスタマイズおよびOEM対応
We provide flexible customization options to adapt the LW-5.3/16 to specific installation constraints and end-user requirements:
- Skid-Mounted Packages: Pre-assembled compressor, motor, cooler, and control panel on a structural steel skid with forklift pockets and lifting eyes. Reduces field installation to electrical connection and cooling water hookup only.
- Mobile Trailer Units: The LW-5.3/16 can be mounted on a road-legal trailer with integrated diesel generator and cooling system, creating a fully mobile high-pressure nitrogen supply unit for construction sites, pipeline maintenance, and emergency response.
- PLCとリモート監視： Optional Siemens LOGO! or S7-1200 PLC with 7-inch HMI touchscreen, Ethernet connectivity, and SMS/email alarm notifications. Compatible with Modbus TCP/IP for SCADA integration.
- Acoustic Enclosures: Compact IP54-rated sound enclosure reducing noise from 84 dB(A) to 68 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments.
- OEMおよびプライベートブランド： Custom paint schemes, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators.
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. Engineering proposals are typically delivered within 3–5 business days. Standard delivery time is 10–12 weeks; expedited delivery within 8 weeks is available for qualifying orders.
Case Study: Pharmaceutical Cylinder Filling Operation
クライアント： A pharmaceutical gas supplier in Southeast Asia specializing in medical-grade nitrogen
チャレンジ： The client’s existing oil-lubricated high-pressure nitrogen compressor (10 years in service) was experiencing progressive oil carryover into the nitrogen product during cylinder filling operations. Oil contamination levels reached 1.5 mg/m³, far exceeding the 0.1 mg/m³ limit required for medical-grade nitrogen certification. The oil was also contaminating the cylinder filling manifold, requiring monthly cleaning and replacement of O-rings and seals.
解決： 私たちは供給しました LW-5.3/16 oil-free nitrogen compressor as the primary booster, feeding a downstream high-pressure booster pump for final cylinder charging. The unit was mounted on a custom skid with integrated intercooler, aftercooler, and a Siemens LOGO! PLC control panel. A 1 m³ surge vessel was installed upstream to buffer pressure fluctuations from the membrane nitrogen generator supplying the compressor.
Results After 18 Months:
- 窒素油含有量： 1.5 mg/m³から0.01 mg/m³未満に減少, achieving ISO 8573-1 Class 0 and medical-grade certification
- Cylinder filling manifold cleaning: 脱落, reducing labor costs by $8,000/year
- O-ring and seal replacement: Reduced by 90%, saving $3,500/year in consumables
- Maintenance burden: One scheduled service per year versus quarterly overhauls
- Customer complaints: Zero since commissioning, with nitrogen purity consistently exceeding specifications
“The LW-5.3/16 has been a game-changer for our medical nitrogen business. We no longer worry about oil contamination, and our customers have noticed the improved consistency in gas quality. The payback period was just over 2 years.” — Operations Manager, Pharmaceutical Gas Supplier
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
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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 and chemical process applications.
MW Series Medium-Pressure Compressors
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当社の包括的な概要については、 工業用窒素圧縮機 portfolio, including oil-free oxygen compressors, hydrogen compressors, and specialty gas solutions, please contact our engineering team or browse our online catalog.
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