설명
LW-25/10 Nitrogen Compressor – High-Pressure Oil-Free N2 Booster for 1.00 MPa Industrial Applications
Engineered to deliver 25 m³/min at 1.00 MPa discharge pressure, the LW-25/10 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, pipeline boosting, and demanding petrochemical process applications. Zero lubricant contamination, continuous-duty rated, and optimized for 24/7 industrial operation at elevated pressure.
제품 개요
그만큼 LW-25/10 nitrogen compressor represents a specialized high-pressure solution within our oil-free piston compressor portfolio, engineered for applications where both substantial flow and elevated discharge pressure are non-negotiable requirements. With a rated capacity of 25 m³/min 그리고 탁월한 1.00 MPa discharge pressure, this unit occupies a unique position at the intersection of high-flow and high-pressure nitrogen compression.
What distinguishes the LW-25/10 from conventional high-pressure alternatives is its 완전 무오일 압축 메커니즘. The piston rings and rider bands are fabricated from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This intrinsic oil-free characteristic delivers ISO 8573-1 클래스 0 인증 natively, making the unit immediately suitable for the most demanding applications including food-grade nitrogen, pharmaceutical process gas, semiconductor fabrication, and petrochemical reactor inerting without additional downstream purification.
압축기는 다음을 사용합니다. 2단 2열(two 列 级) configuration that carefully manages the high pressure ratio required for 1.00 MPa discharge. By dividing the compression work across two cylinders with an optimized inter-stage pressure, the LW-25/10 maintains thermal stability and preserves the integrity of the PTFE sealing elements even under sustained maximum-load operation. The robust cast-iron frame and precision-balanced forged steel crankshaft are rated for a minimum service life of 120,000시간 표준 유지보수 절차에 따라.
Technical Specifications – LW-25/10
| 매개변수 | 값 | 단위 |
|---|---|---|
| 모델 | LW-25/10 | – |
| 무늬 | 2단, 2열(two 列 级) | – |
| 용량 | 25 | m³/min |
| 토출 압력 | 1.00 | MPa |
| 압축기 크기 (길이 × 너비 × 높이) | 2500 × 1600 × 2700 | mm |
| 무게 | 4.50 | 티 |
| 힘 | 200 | 킬로와트 |
| 전압 | 380 / 6k 또는 10k | 다섯 |
| 가스 매체 | 질소(N₂) | – |
| 매끄럽게 하기 | 오일 프리 | – |
* 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. High-Temperature Oil-Free PTFE Sealing Technology
The LW-25/10 utilizes a proprietary 자가 윤활 피스톤 링 및 라이더 밴드 어셈블리 manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates, specifically formulated for high-pressure service. This material 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 engineered for the elevated discharge temperatures associated with 1.00 MPa operation, maintaining dimensional stability and sealing integrity up to 190°C. For operators in regulated industries, this delivers ISO 8573-1 클래스 0 준수 without the capital cost, maintenance burden, or energy penalty of downstream oil-filtration systems.
2. Optimized Two-Stage High-Pressure Thermodynamic Design
그만큼 2단계 압축 아키텍처 of the LW-25/10 is thermodynamically optimized for the demanding 1.00 MPa discharge pressure target. By carefully dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder with an optimized inter-stage pressure, the compressor achieves a significantly lower mean effective temperature per stage compared to single-stage designs. A 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 advanced thermal management is essential for preserving PTFE ring integrity at high pressure ratios and extends valve plate service life by approximately 45% versus single-stage alternatives.
3. Reinforced Cast-Iron Frame with Force Balance
본체는 다음 재료로 주조됩니다. GG25 회주철 (equivalent to ASTM A48 Class 30B) with reinforced wall sections and 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. This mechanical advantage is particularly valuable for the LW-25/10 given its high-pressure operation, where reciprocating forces are substantially higher than low-pressure equivalents. The reduced vibration transmission permits installation on a lighter reinforced concrete inertia block (minimum 8 tonnes versus 12+ tonnes for single-row high-pressure equivalents), reducing civil engineering costs.
4. Flexible Voltage Configuration for Industrial Integration
The LW-25/10 is driven by a 200 kW induction motor available in 380V, 6kV, or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The flexible voltage options allow direct integration into diverse industrial electrical infrastructures: the 380V configuration suits facilities with existing low-voltage distribution, while the 6kV and 10kV options eliminate the need for step-down transformers in large industrial plants with medium-voltage bus systems. This electrical versatility reduces infrastructure costs and improves overall energy efficiency by minimizing transformation losses.
응용 시나리오
High-Pressure Nitrogen Injection for Petrochemical Reactors
In petrochemical and refining operations, the LW-25/10 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, emergency nitrogen injection, and process vessel purging. The 1.00 MPa discharge pressure is sufficient to overcome the operating pressures of typical fixed-bed reactors, fluid catalytic cracking units, and hydrocracker systems, allowing direct nitrogen injection without intermediate boosting. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround campaigns. 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.
고압 VPSA 질소 부스터 스테이션
For VPSA nitrogen generators producing high-purity nitrogen at near-atmospheric pressure, the LW-25/10 high-pressure nitrogen booster compresses the low-pressure product to 1.00 MPa for demanding distribution applications. The elevated discharge pressure is particularly valuable for VPSA installations serving high-pressure process consumers, long-distance pipeline networks with significant friction losses, or facilities requiring nitrogen at pressure for direct injection into process vessels. The oil-free compression path is absolutely essential because hydrocarbon contamination would permanently poison the carbon molecular sieve adsorbent, degrading separation efficiency and requiring costly adsorbent replacement.
Pipeline Nitrogen Boosting & Pressure Maintenance
Industrial gas distribution networks spanning multiple kilometers require nitrogen at elevated pressure to overcome pipeline friction losses and maintain adequate flow at remote consumers. The LW-25/10’s 1.00 MPa discharge pressure provides sufficient head for distribution over distances up to 5 km through DN200 pipelines, making it suitable for centralized nitrogen supply to large industrial complexes, chemical parks, and integrated manufacturing facilities. The 25 m³/min capacity supports multiple high-pressure consumers simultaneously, including reactor inerting systems, tank blanketing stations, and emergency nitrogen injection points.
High-Pressure Food Packaging & Modified Atmosphere Systems
Large-scale food packaging facilities with high-speed MAP (Modified Atmosphere Packaging) lines require nitrogen at elevated pressure to achieve rapid gas displacement in packaging chambers. The LW-25/10’s 1.00 MPa discharge pressure enables fast-fill nitrogen injection, reducing cycle times and increasing packaging line throughput. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-grade nitrogen. The absence of oil contamination eliminates risks of off-flavors, rancidity, or product discoloration that can occur with lubricated compressors in food-contact applications.
자재 및 시공
The LW-25/10 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal resistance, and extended operational life:
| 요소 | 재료 | 사양 |
|---|---|---|
| 실린더 블록 | 회색 주철 | GG25 / HT250, reinforced walls, integral cooling jackets |
| 크랭크 샤프트 | 단조 합금강 | 42CrMo4, Q&T, ISO 1940 G2.5 동적 평형 |
| 피스톤 링 | PTFE-유리-청동 복합재 | Self-lubricating, high-temp rated to 190°C |
| 라이더 밴드 | PTFE 복합재 | 피스톤 가이드, 마모 방지, 마모율 <0.04 mm/1000h |
| 밸브 플레이트 | 스테인리스 스틸 | SS316, high-pressure concentric ring spring-loaded design |
| 커넥팅 로드 | 배빗 베어링이 적용된 단조강 | 정밀 가공 및 오일 윤활 방식의 빅 엔드 |
| 인터쿨러 | 탄소강 쉘 / SS316 튜브 | ASME VIII Div.1, 1.5배 수압 시험, 30분 유지 |
| 애프터쿨러 | 탄소강 쉘 / SS316 튜브 | High-efficiency finned tube, 32°C cooling water rated |
| 고압 배관 | Seamless Carbon Steel | ASTM A106 Grade B, Schedule 80 |
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 LW-25/10 has a dry weight of 4.50 tonnes and a center of gravity approximately 950 mm above the baseplate. Due to the two-row opposed-cylinder design, unbalanced forces are significantly reduced despite the high-pressure operation, permitting installation on a reinforced concrete inertia block of 8–10 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz) to prevent vibration transmission. 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.
냉각수 시스템 설계
냉각수 수요는 대략 다음과 같습니다. 28 m³/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), suspended solids < 30 mg/L, and total hardness < 300 mg/L as CaCO₃. 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 corrosion in the high-pressure cooling circuits.
예방 정비 일정
| 간격 | 서비스 항목 | 조치 필요 |
|---|---|---|
| 일일 | 운영 점검 | Check vibration levels, abnormal noise, cooling water flow, discharge temperature and pressure |
| 250시간 | 밸브 플레이트 검사 | 흡입/배출 밸브를 분리하여 탄소 침전물, 스프링 피로 또는 균열 여부를 점검하십시오. |
| 1,000시간 | 피스톤 링 마모 평가 | 링 홈 간극을 측정하고, 간극이 0.20mm를 초과하면 링을 교체하십시오. |
| 4,000시간 | 중간 정비 | 피스톤 링, 라이더 밴드 및 밸브 플레이트 어셈블리를 모두 교체하십시오. |
| 8,000시간 | 대대적인 개편 | 크랭크축 저널을 점검하고, 메인 베어링 간극을 측정하며, 간극이 0.08mm보다 크면 베어링을 교체하십시오. |
The oil-free design of the LW-25/10 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 밴드이 제품들은 일반적으로 청정 질소 환경에서 4,000~6,000시간의 수명을 제공합니다. 이러한 유지보수 간소화는 인건비 절감, 예비 부품 재고 감소, 장비 가용성 향상으로 이어집니다.
규정 준수 및 안전 인증
The LW-25/10 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC 섹션 VIII Div.1, GB 150-2011, PED 2014/68/EU 모듈 A
IEC 60034-1(IE3 효율), IEC 60204-1, ISO 12100 기계 안전
ISO 8573-1 0등급(유지 함량) 기준 충족, TÜV 라인란트에서 독립적으로 테스트 완료
ISO 9001:2015(품질경영), ISO 14001:2015(환경경영)
Nitrogen is classified as a simple asphyxiant gas. All LW-25/10 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas where nitrogen leakage could accumulate. Ventilation systems must be engineered 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 into enclosed compressor rooms must include portable oxygen monitors and a buddy-system protocol. Additionally, the 1.00 MPa discharge pressure requires all downstream piping and vessels to be rated for the maximum working pressure with appropriate safety relief devices.
성과 및 효율성 분석
The LW-25/10 achieves a specific power consumption of approximately 8.00 kW per m³/min of nitrogen delivered at 1.00 MPa discharge pressure. This efficiency metric is respectable for an oil-free piston compressor operating at a high pressure ratio, reflecting the thermodynamic challenges of compressing nitrogen to 1.00 MPa. For comparison, oil-lubricated screw compressors in similar high-pressure applications typically consume 8.5–9.5 kW/m³/min, while diaphragm compressors (often selected for oil-free high-pressure service) can exceed 12 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the LW-25/10’s efficiency advantage generates approximately 40,000–100,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $3,200–$8,000 in direct operating cost reduction per year. However, the primary economic driver for LW-25/10 selection is typically the elimination of oil-related consumables and downstream purification equipment rather than marginal energy savings.
그만큼 고압 질소 압축의 총 소유 비용 is significantly reduced by the absence of oil in the compression path. A typical oil-lubricated compressor of this pressure rating requires coalescing filters, activated carbon adsorbers, oil monitoring instrumentation, and periodic oil changes that collectively add $8,000–$15,000 in annual operating costs. The LW-25/10’s oil-free design eliminates these expenses entirely, while also removing the 3–5% energy penalty associated with downstream oil-removal equipment.
맞춤 제작 및 OEM 역량
We provide comprehensive customization options to adapt the LW-25/10 to specific site conditions, integration requirements, and end-user specifications:
- 스키드 장착형 턴키 패키지: The compressor, motor, intercooler, aftercooler, high-pressure instrumentation, and control panel are pre-assembled on a structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces field commissioning time by approximately 60% and minimizes startup risks.
- 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: 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 integration with plant DCS/SCADA systems. Automatic load/unload control and variable frequency drive (VFD) compatibility optimize part-load efficiency.
- High-Pressure Package Options: Integrated high-pressure receiver vessels, pressure regulation skids, and nitrogen distribution manifolds can be supplied as part of a complete system package. All high-pressure components are designed and tested to ASME BPVC standards.
- 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 Reactor Nitrogen Injection System
고객: A major petrochemical complex in the Middle East operating polyethylene and polypropylene production units
도전: The client’s existing oil-lubricated nitrogen compressor (American brand, 12 years in service) was experiencing progressive oil carryover into the nitrogen injection system used for reactor inerting and catalyst bed preservation. Oil contamination levels reached 3.5 mg/m³, exceeding the 0.1 mg/m³ limit specified by the catalyst supplier. The oil was deactivating the Ziegler-Natta catalyst, reducing polymer yield by 2.8% and requiring premature catalyst replacement at a cost of $180,000 per campaign. Additionally, the compressor’s 0.70 MPa discharge pressure was insufficient for new high-pressure reactor designs requiring 0.95 MPa nitrogen.
해결책: 우리는 공급했습니다 LW-25/10 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with integrated intercooler, aftercooler, high-pressure receiver vessel, and a Siemens S7-1200 PLC control panel with DCS integration. The 1.00 MPa discharge pressure met the new reactor requirements with margin, while the oil-free design eliminated catalyst contamination. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from multiple reactor units.
18개월 후 정량화된 결과:
- 질소 오일 함량: Reduced from 3.5 mg/m³ to <0.01 mg/m³ISO 8573-1 클래스 0 인증을 획득했습니다.
- Catalyst deactivation incidents: 완전히 제거됨, restoring polymer yield to design specifications
- Catalyst replacement frequency: Extended from 12 months to 24 months, saving $180,000 per cycle
- 연간 유지 관리 비용: 48%만큼 감소 through elimination of oil-related repairs and separator overhauls
- 예기치 않은 다운타임: 이벤트 없음 in 18 months of continuous operation
“The LW-25/10 solved our catalyst contamination problem permanently. The 1.00 MPa pressure gives us the margin we need for new reactor designs, and the oil-free design has eliminated our most persistent operational headache. The payback was under 14 months.” — Process Engineering Manager, Petrochemical Complex
자주 묻는 질문 및 선택 가이드
관련 제품 및 솔루션
LW 시리즈 대용량 질소 압축기
High-flow oil-free piston compressors (30–130 m³/min) for cryogenic ASU backup, VPSA boosting, and industrial pipeline distribution. Discharge pressures from 0.30 to 1.00 MPa.
DW 시리즈 고압 질소 압축기
Designed for discharge pressures from 1.00 MPa to 2.00 MPa, the DW series covers ultra-high-pressure nitrogen injection, pipeline boosting, and chemical synthesis applications.
ZW 시리즈 다단식 무오일 압축기
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.
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.
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