DW-60/8 Nitrogen Compressor – Heavy-Duty Oil-Free N2 Booster for High-Pressure Industrial Gas Networks

Engineered to deliver 60 m³/min at 0.80 MPa discharge pressure, the DW-60/8 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for large-scale cryogenic air separation, high-pressure VPSA booster stations, and demanding petrochemical pipeline distribution. Zero lubricant contamination, continuous-duty rated, and optimized for 24/7 industrial operation at elevated pressure.

제품 개요

그만큼 DW-60/8 nitrogen compressor represents a significant advancement in our oil-free piston compressor portfolio, engineered to meet the dual demands of high flow capacity and elevated discharge pressure that characterize the most challenging industrial nitrogen applications. With a formidable 60m³/min 용량 paired with a 0.80 MPa 토출 압력, this unit occupies the upper tier of our DW series, bridging the gap between standard nitrogen boosting and high-pressure industrial gas distribution.

What distinguishes the DW-60/8 from conventional lubricated alternatives is its intrinsically oil-free compression mechanism. The piston rings and rider bands are fabricated from self-lubricating PTFE composite materials that operate entirely without hydrocarbon lubricants, ensuring the nitrogen product stream remains completely free of oil contamination. This design philosophy achieves ISO 8573-1 클래스 0 인증을 기본적으로 제공합니다., eliminating the need for costly downstream oil-filtration equipment that would otherwise be mandatory in food-grade, pharmaceutical, and electronics-grade nitrogen applications.

압축기 아키텍처는 다음을 따릅니다. 2단 2열(two 列 级) configuration that optimally distributes the substantial pressure ratio across two compression cylinders. This staged approach is critical for managing the thermal stresses associated with compressing nitrogen to 0.80 MPa while preserving the integrity of the PTFE sealing elements. Each stage incorporates an independent high-efficiency intercooler, maintaining gas temperatures within safe operating envelopes even during sustained maximum-capacity operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft assembly are engineered for a minimum service life of 120,000시간 표준 유지보수 절차에 따라.

Technical Specifications – DW-60/8

* 모든 사양은 표준 참조 조건(ISO 1217, 부록 C)에서 측정되었습니다. 실제 성능은 현장 고도, 주변 온도 및 흡입구 조건에 따라 달라질 수 있습니다.

주요 특징 및 엔지니어링 장점

1. 고온 PTFE 복합재 밀봉 기술

The DW-60/8 utilizes a proprietary 자가 윤활 피스톤 링 및 라이더 밴드 어셈블리 manufactured from advanced PTFE composites reinforced with glass fiber, carbon fiber, and bronze particulates. This material formulation achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover into the nitrogen product stream. The rings are specifically engineered for the elevated discharge temperatures associated with 0.80 MPa operation, maintaining dimensional stability and sealing integrity up to 185°C. For industrial gas operators, this translates to ISO 8573-1 클래스 0 준수 without the capital expenditure, maintenance burden, or energy penalty of downstream oil-filtration systems.

2. 고급 2단계 열역학적 최적화

그만큼 2단계 압축 아키텍처 of the DW-60/8 is thermodynamically optimized for the demanding 0.80 MPa discharge pressure target. By dividing the substantial pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor achieves a significantly lower mean effective temperature per stage compared to single-stage designs. A dedicated high-efficiency shell-and-tube intercooler between stages removes the heat of compression, maintaining discharge temperatures below 160°C even at maximum continuous load. This thermal management strategy is essential for preserving PTFE ring integrity at elevated pressure and extends valve plate service life by approximately 45% versus single-stage alternatives operating at equivalent pressure ratios.

3. Extended Horizontal Frame for Superior Stability

본체는 다음 재료로 주조됩니다. GG25 회주철 (equivalent to ASTM A48 Class 30B) with integral cooling water passages. The 2열 대향 실린더 배열 provides natural first-order force cancellation, reducing unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs. The extended horizontal layout (5000 mm length) provides exceptional structural rigidity and bearing support span, minimizing crankshaft deflection under the substantial torque loads of 60 m³/min compression. This mechanical advantage permits installation on a reinforced concrete inertia block of minimum 12 tonnes, significantly reducing civil engineering costs compared to equivalent single-row compressors.

4. Medium-Voltage Direct Drive for Industrial Power Systems

The DW-60/8 is driven by a 350kW 중전압 유도 전동기 available in either 6kV or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The medium-voltage drive eliminates the need for oversized low-voltage switchgear and heavy-gauge cabling that would be required for a 380V motor of this power rating. Direct integration into industrial medium-voltage distribution networks reduces electrical infrastructure costs, minimizes I²R losses in power cabling, and improves overall energy efficiency. For large-scale industrial facilities where 6kV or 10kV bus systems are standard, the DW-60/8 offers seamless electrical compatibility without additional transformation equipment.

응용 시나리오

Large-Scale Cryogenic Air Separation Distribution

In large cryogenic ASU facilities producing 2,500–6,000 Nm³/h of gaseous nitrogen, the DW-60/8 serves as the primary high-pressure nitrogen booster between the cold box and the industrial distribution network. Its 60 m³/min capacity exceeds the output of most medium-scale ASUs, providing reserve capacity for peak demand periods and allowing one compressor to serve multiple ASU trains. The 0.80 MPa discharge pressure provides substantial head for long-distance pipeline distribution to downstream consumers such as integrated steel mills, petrochemical complexes, LNG regasification terminals, and power generation facilities. The oil-free design is critical because any oil contamination would compromise nitrogen purity across the entire distribution network, affecting sensitive processes in semiconductor, pharmaceutical, and food manufacturing facilities served by the same header.

고압 VPSA 질소 부스터 스테이션

대기압에 가까운 압력에서 99.5~99.9% 순도의 질소를 생산하는 대형 VPSA 질소 발생기의 경우, DW-60/8 nitrogen booster compresses the low-pressure product to 0.80 MPa for high-pressure distribution. The elevated discharge pressure is particularly valuable for VPSA installations serving multiple consumers through a centralized header, where pressure losses across the distribution network can be substantial. The 60 m³/min capacity allows the DW-60/8 to serve as the primary booster for multiple VPSA trains operating in parallel, or to provide peak-shaving capacity during high-demand periods. The oil-free compression path is absolutely essential because hydrocarbon contamination would irreversibly poison the carbon molecular sieve adsorbent, permanently degrading separation efficiency and necessitating costly adsorbent replacement.

석유화학 고압 공정 질소

In petrochemical and refinery operations, the DW-60/8 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, pipeline purging, emergency vessel injection, and hydrostatic testing. The 0.80 MPa discharge pressure is sufficient to overcome the pressure ratings of typical process vessels, reactor systems, and high-pressure pipeline segments, allowing direct nitrogen injection without intermediate boosting. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround and maintenance campaigns that may span several weeks. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free to prevent catalyst poisoning or product contamination.

LNG Plant Purge & Inerting Operations

LNG liquefaction and regasification facilities require large volumes of high-pressure nitrogen for cold box purging, pipeline inerting, storage tank blanketing, and emergency gas displacement. The DW-60/8’s 60 m³/min capacity and 0.80 MPa discharge pressure are ideally matched to the demanding requirements of LNG operations, where nitrogen must be delivered at sufficient pressure to overcome cryogenic system back-pressures and maintain positive inerting gas flow during all operational phases. The oil-free design prevents oil contamination of cryogenic heat exchangers and molecular sieve dryers, which would cause fouling, reduced heat transfer efficiency, and potential safety hazards in cryogenic service.

자재 및 시공

The DW-60/8 is constructed from premium materials selected for nitrogen compatibility, high-pressure service integrity, and extended operational life under demanding conditions:

모든 압력 지지 부품은 다음 사항에 따라 엄격하게 설계 및 제작됩니다. ASME BPVC 섹션 VIII 부문 1 또는 중국 GB 150 표준을 준수합니다. 모든 용접 이음매는 ASME 섹션 V, 2항에 따라 100% 방사선 투과 검사(RT)를 거치며, 완성된 모든 압력 용기는 최대 허용 작동 압력(MAWP)의 1.5배에 해당하는 압력으로 최소 30분 동안 수압 시험을 거칩니다.

설치 및 유지 관리 지침

기초 및 구조 요구사항

The DW-60/8 has a dry weight of 6.00 tonnes and a center of gravity approximately 850 mm above the baseplate. The two-row opposed-cylinder design minimizes unbalanced forces, permitting installation on a reinforced concrete inertia block of 12–15 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz) to prevent vibration transmission to adjacent structures and sensitive instrumentation. 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. The extended 5000 mm length requires a minimum machinery room dimension of 7000 mm to accommodate the compressor plus maintenance clearances.

냉각수 시스템 설계

냉각수 수요는 대략 다음과 같습니다. 60m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS316 tube corrosion in the coolers), suspended solids < 30 mg/L, and total hardness < 300 mg/L as CaCO₃. For sites with marginal water quality or high ambient temperatures, a closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended to prevent scale formation, corrosion, and biological fouling.

예방 정비 일정

The oil-free design of the DW-60/8 dramatically reduces maintenance complexity compared to lubricated alternatives. There are no oil changes to schedule, no lubricating oil samples to analyze, no oil filter elements to replace, and no oil separator cartridges to monitor. The primary consumable wear items are the PTFE 피스톤 링 및 라이더 밴드, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions. This maintenance simplification translates to lower labor costs, reduced spare parts inventory, and higher equipment availability for continuous industrial operations.

규정 준수 및 안전 인증

The DW-60/8 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

성과 및 효율성 분석

The DW-60/8 achieves a 약 5.83kW/m³/min의 비전력 소비량 of nitrogen delivered at 0.80 MPa discharge pressure. This efficiency metric is competitive for an oil-free piston compressor operating at a substantial pressure ratio, positioning the unit favorably within the 50–70 m³/min high-pressure capacity class. For comparison, oil-lubricated screw compressors in similar high-pressure applications typically consume 6.2–7.0 kW/m³/min, while legacy single-stage piston designs may exceed 7.5 kW/m³/min at equivalent discharge pressures.

Over a standard 8,000-hour annual operating schedule, the DW-60/8’s efficiency advantage generates approximately 144,000–336,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $11,520–$26,880 in direct operating cost reduction per year. When combined with the complete elimination of oil-related consumables (lubricating oil, filter elements, separator cartridges, waste oil disposal, and oil analysis), the 질소 압축의 총 소유 비용 10년의 작동 수명 동안 약 22~32%가 감소할 것으로 추정됩니다.

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 and pressure rating requires coalescing filters, activated carbon adsorbers, and continuous oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output. The DW-60/8’s oil-free design removes this parasitic load entirely, further improving effective system efficiency and reducing the total electrical demand of the nitrogen compression station.

맞춤 제작 및 OEM 역량

We offer comprehensive customization options to adapt the DW-60/8 to specific site conditions, integration requirements, and end-user specifications:

• 스키드 장착형 턴키 패키지: 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 through factory pre-testing of all systems.
• 위험 지역 구성: ATEX Zone 2 및 IECEx 규격을 준수하는 모터 및 전기 인클로저는 폭발성 분위기가 간헐적으로 발생할 수 있는 석유화학 시설에 설치할 수 있습니다. 제어 시스템에는 통합 가스 감지 및 자동 환기 연동 장치를 포함할 수 있습니다.
• 고급 공정 제어: 옵션 사양으로 Siemens S7-1200 또는 Allen-Bradley CompactLogix PLC(10인치 HMI 터치스크린 포함), Modbus TCP/IP 또는 OPC-UA를 통한 원격 모니터링, 공장 DCS/SCADA 시스템과의 완벽한 통합이 가능합니다. 자동 부하/언로드 제어 및 가변 주파수 드라이브(VFD) 호환성을 통해 부분 부하 효율을 최적화하고 시동 시 기계적 마모를 줄입니다.
• 환경 보호 시스템: 해안 또는 해양 설비용 C5-M 해양 등급 코팅 시스템, 최대 55°C의 주변 온도에 적합한 열대 지역용 전기 부품, 그리고 1미터 거리에서 소음 방출을 85dB(A)에서 72dB(A)로 줄여주는 IP54 등급 방음 인클로저(별도의 압축기실 없이 실내 설치에 적합) 등이 있습니다.
• OEM 및 자체 브랜드 프로그램: 가스 장비 유통업체 및 시스템 통합업체를 위해 맞춤형 도색 색상, 브랜드 명판, 현지화된 문서 패키지를 제공합니다. 기술 매뉴얼, 예비 부품 목록, 유지보수 절차는 여러 언어로 제공 가능합니다.

사용자 지정 구성은 다음에서 이용 가능합니다. 최소 주문 수량 1개엔지니어링 검토 및 제안서 작성에는 일반적으로 5~7영업일이 소요됩니다. 표준 납기는 12~14주이며, 재주문은 주문 확인 후 8~10주 이내에 배송됩니다.

Case Study: Petrochemical Complex Nitrogen Distribution Upgrade

고객: A major petrochemical complex in the Middle East with ethylene cracking, polyethylene production, and aromatic processing units

도전: The complex’s existing nitrogen supply consisted of three oil-lubricated compressors (European brand, 20 years in service) feeding a common 0.60 MPa distribution header. The compressors were experiencing progressive oil carryover into the nitrogen stream, contaminating catalyst beds in the ethylene cracking unit and causing unplanned shutdowns. The 0.60 MPa pressure was also insufficient for new high-pressure reactor inerting requirements. Maintenance costs had escalated to $120,000/year, and spare parts availability was becoming problematic due to the age of the equipment.

해결책: We supplied a DW-60/8 oil-free nitrogen compressor as the primary replacement unit, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel with full SCADA integration. The 0.80 MPa discharge pressure met the new reactor inerting requirements, while the oil-free design eliminated catalyst bed contamination. A 5 m³ surge vessel was installed upstream to buffer demand fluctuations from the multiple process units. The existing 0.60 MPa compressors were retained as standby units, providing redundancy during maintenance periods.

24개월 후 정량화된 결과:

• 질소 오일 함량: Reduced from 5.1 mg/m³ to <0.01 mg/m³ISO 8573-1 클래스 0 인증을 획득했습니다.
• Catalyst bed contamination incidents: 완전히 제거됨, improving ethylene cracking unit availability by 3.5%
• 연간 유지 관리 비용: 48%만큼 감소 ($120,000 to $62,400) through elimination of oil-related repairs and improved parts availability
• 에너지 소비량: Improved by 5.9% versus the primary replaced unit, saving approximately $16,800/year
• 예기치 않은 다운타임: 이벤트 없음 24개월 연속 운전

“The DW-60/8 has completely transformed our nitrogen reliability. The elimination of oil contamination has been the single biggest improvement—our catalyst beds are running cleaner than ever, and our unplanned shutdowns due to nitrogen issues have dropped to zero. The 0.80 MPa pressure also gives us the flexibility we needed for our new reactor systems.” — Process Engineering Manager, Petrochemical Complex

자주 묻는 질문 및 선택 가이드

관련 제품 및 솔루션

저희에 대한 포괄적인 개요를 보시려면 산업용 질소 압축기 오일프리 산소 압축기, 수소 압축기, 이산화탄소 압축기 및 맞춤형 특수 가스 솔루션을 포함한 당사 제품 포트폴리오에 대한 자세한 내용은 애플리케이션 엔지니어링 팀에 문의하거나 온라인 제품 카탈로그를 참조하십시오.

고압 질소 시스템 업그레이드를 고려하고 계신가요?

당사의 애플리케이션 엔지니어는 고객의 질소 유량 요구 사항, 흡입 조건, 토출 압력 목표 및 통합 제약 조건을 평가하기 위해 대기하고 있습니다. 문의 접수 후 48시간 이내에 무료 기술 제안서, 기초 배치 도면, 배관 및 계측 다이어그램(P&ID) 및 상세한 총 소유 비용(TCO) 분석을 제공해 드립니다.

이메일: [email protected] 24시간 이내 답변드리겠습니다.