설명
LW-25/16 Nitrogen Compressor – High-Pressure Oil-Free N2 Booster for 1.60 MPa Industrial Applications
Engineered to deliver 25 m³/min at 1.60 MPa discharge pressure, the LW-25/16 is a two-stage, two-row oil-free piston nitrogen compressor designed for high-pressure nitrogen injection, pipeline boosting, and demanding petrochemical process applications. Zero lubricant contamination, continuous-duty rated, and built for 24/7 operation at elevated pressure.
제품 개요
그만큼 LW-25/16 nitrogen compressor occupies a specialized position within our oil-free piston compressor portfolio, bridging the gap between medium-pressure nitrogen distribution and high-pressure process applications. With a rated capacity of 25 m³/min 그리고 탁월한 1.60 MPa discharge pressure, this unit addresses the most demanding nitrogen compression requirements in industrial gas infrastructure where both substantial flow and elevated pressure are simultaneously required.
What distinguishes the LW-25/16 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 specifically formulated for high-pressure service. These components operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination even at the elevated temperatures and pressures associated with 1.60 MPa discharge. This intrinsic oil-free characteristic delivers ISO 8573-1 클래스 0 인증 natively, eliminating the need for costly downstream oil-removal systems that would otherwise be mandatory in high-pressure applications.
압축기는 다음을 사용합니다. 2단 2열(two 列 级) configuration that is essential for managing the extreme pressure ratio required to achieve 1.60 MPa discharge from near-atmospheric inlet conditions. The staged compression distributes thermal load across two cylinders, with an independent high-efficiency intercooler between stages maintaining gas temperatures within safe operating limits. The robust cast-iron frame and precision-forged crankshaft are engineered to withstand the substantial mechanical forces generated by high-pressure operation, with a rated service life exceeding 100,000 hours 표준 유지보수 절차에 따라.
Technical Specifications – LW-25/16
| 매개변수 | 값 | 단위 |
|---|---|---|
| 모델 | LW-25/16 | – |
| 무늬 | 2단, 2열(two 列 级) | – |
| 용량 | 25 | m³/min |
| 토출 압력 | 1.60 | 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. 고압 무유 PTFE 밀봉 기술
The LW-25/16 utilizes a proprietary high-pressure self-lubricating piston ring and rider band system manufactured from advanced PTFE composites reinforced with high-strength glass fiber and bronze particulates. This material formulation is specifically engineered for the extreme pressure differentials and elevated temperatures encountered at 1.60 MPa discharge pressure. The rings achieve a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating oil contamination risk. For high-pressure nitrogen users in petrochemical, pharmaceutical, and specialty gas applications, this delivers ISO 8573-1 클래스 0 준수 without the complexity, cost, and reliability concerns of downstream oil-filtration systems operating at elevated pressure.
2. 극한 압력비에 대한 2단 압축
그만큼 2단계 압축 아키텍처 is absolutely critical for achieving 1.60 MPa discharge from atmospheric inlet conditions, representing an overall pressure ratio of approximately 16:1. By dividing this extreme ratio between a low-pressure cylinder and a high-pressure cylinder, the LW-25/16 limits the discharge temperature of each stage to below 160°C, preserving the structural integrity of the PTFE sealing elements. A high-efficiency shell-and-tube intercooler between stages removes the substantial heat of compression, with cooling water flow designed to maintain inter-stage temperatures below 45°C even at maximum continuous load. This thermal management extends valve plate life by approximately 50% compared to single-stage designs attempting equivalent pressure ratios.
3. Reinforced Heavy-Duty Frame for High-Pressure Operation
본체는 다음 재료로 주조됩니다. GG30 gray cast iron (upgraded from the GG25 used in lower-pressure models) with thicker wall sections and reinforced bearing pedestals to withstand the substantially higher mechanical loads generated by 1.60 MPa discharge pressure. 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 important for high-pressure compressors where the peak cylinder forces are significantly elevated. The forged steel crankshaft is dynamically balanced to ISO 1940 G2.5 standards and features enlarged bearing journals to accommodate the higher bearing loads.
4. Flexible Voltage Configuration for Industrial Integration
The LW-25/16 is available with a 200 kW drive motor in three voltage configurations: 380V for facilities with low-voltage distribution infrastructure, or 6kV/10kV for direct integration into medium-voltage industrial networks. The 380V option is ideal for smaller installations or retrofit projects where medium-voltage infrastructure is not available. The 6kV and 10kV options eliminate the need for step-down transformers in large industrial facilities, reducing electrical infrastructure costs and improving overall energy efficiency. All motor configurations conform to IEC 60034-1 efficiency class IE3.
응용 시나리오
High-Pressure Nitrogen Pipeline Boosting
In industrial gas distribution networks spanning multiple facilities or large plant sites, the LW-25/16 serves as a high-pressure nitrogen booster station to overcome pipeline friction losses and maintain adequate pressure at remote consumption points. Its 1.60 MPa discharge pressure provides sufficient head for distribution over distances exceeding 5 km, making it ideal for centralized nitrogen supply to multiple process units, storage tank farms, and remote loading stations. The 25 m³/min capacity supports medium-scale industrial complexes with multiple simultaneous nitrogen consumers. The oil-free design is critical in pipeline applications because any oil contamination would propagate throughout the entire distribution network, potentially affecting all downstream consumers.
Petrochemical Reactor Inerting & Catalyst Preservation
Petrochemical reactors, catalytic crackers, and hydroprocessing units require high-pressure nitrogen for reactor inerting during startup and shutdown, catalyst bed preservation during standby periods, and emergency depressurization. The LW-25/16 high-pressure nitrogen compressor delivers the 1.60 MPa pressure required to overcome reactor system pressures and inject nitrogen directly into process vessels. The oil-free design is absolutely mandatory in these applications because oil contamination would poison expensive catalyst beds, permanently degrading catalytic activity and requiring costly catalyst replacement or regeneration.
Nitrogen Gas Filling & Cylinder Charging Stations
Industrial gas filling stations and cylinder charging facilities require high-pressure nitrogen compressors to fill standard gas cylinders (typically 15 MPa working pressure) and tube trailers (up to 20 MPa). While the LW-25/16’s 1.60 MPa discharge pressure does not directly achieve cylinder filling pressure, it serves as an 중간 부스터 in multi-stage compression trains, compressing nitrogen from atmospheric or low-pressure sources to the suction pressure of high-pressure diaphragm or piston compressors. The oil-free design ensures that nitrogen entering the high-pressure stage is completely uncontaminated, preventing oil accumulation in high-pressure cylinders and tube trailers that could compromise gas purity and create safety hazards.
Food & Beverage High-Pressure Nitrogen Injection
Large-scale food and beverage processing facilities utilize high-pressure nitrogen for product dispensing systems, pressurized packaging, and controlled atmosphere storage at elevated pressure. The LW-25/16’s 1.60 MPa discharge pressure is sufficient for direct injection into pressurized product tanks and dispensing systems without intermediate boosting. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-contact nitrogen. The 25 m³/min capacity supports high-throughput production lines where multiple dispensing stations operate simultaneously.
자재 및 시공
The LW-25/16 is constructed from premium materials specifically selected for high-pressure nitrogen service, thermal stress resistance, and extended operational life:
| 요소 | 재료 | 사양 |
|---|---|---|
| 실린더 블록 | 회색 주철 | GG30 / HT300, reinforced wall sections, integral cooling jackets |
| 크랭크 샤프트 | 단조 합금강 | 42CrMo4, Q&T, enlarged bearing journals, ISO 1940 G2.5 balanced |
| 피스톤 링 | High-Pressure PTFE Composite | Self-lubricating, high-temp rated to 200°C, wear rate <0.04 mm/1000h |
| 라이더 밴드 | PTFE 복합재 | Piston guidance, anti-scuffing, high-pressure rated |
| 밸브 플레이트 | 스테인리스 스틸 | SS316, high-pressure concentric ring spring-loaded design |
| 커넥팅 로드 | 배빗 베어링이 적용된 단조강 | Reinforced big end, oil-lubricated, precision-machined |
| 인터쿨러 | 탄소강 쉘 / SS316 튜브 | High-pressure rated, ASME VIII Div.1, 1.5× hydrotest |
| 애프터쿨러 | 탄소강 쉘 / SS316 튜브 | High-pressure finned tube, 32°C cooling water rated |
| 고압 배관 | Seamless Carbon Steel | ASTM A106 Gr.B, Schedule 80, 100% RT inspected |
모든 압력 지지 부품은 다음 사항에 따라 엄격하게 설계 및 제작됩니다. ASME BPVC 섹션 VIII 부문 1 or Chinese GB 150 standards, with additional safety margins for high-pressure service. 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. High-pressure piping is 100% pneumatically tested at 1.1× MAWP after hydrostatic testing.
설치 및 유지 관리 지침
기초 및 구조 요구사항
The LW-25/16 has a dry weight of 4.50 tonnes and a center of gravity approximately 950 mm above the baseplate. Due to the substantially higher mechanical forces generated by 1.60 MPa discharge pressure, a reinforced concrete inertia block of 9–12 tonnes is required. The block must be mounted on heavy-duty vibration isolators (natural frequency 5–7 Hz) capable of accommodating the elevated dynamic loads. Foundation design must account for the peak cylinder forces, which are significantly higher than those of lower-pressure compressors of equivalent capacity. 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 high-pressure intercooler and aftercooler require particularly effective cooling to manage the substantial heat of compression at 1.60 MPa. Water quality specifications: pH 6.5–8.5, total dissolved solids < 400 mg/L, chloride content < 40 mg/L (critical for SS316 tube corrosion prevention), suspended solids < 25 mg/L, and total hardness < 250 mg/L as CaCO₃. A closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended for all installations to ensure consistent water quality and prevent scale formation in high-pressure heat exchanger tubes.
예방 정비 일정
| 간격 | 서비스 항목 | 조치 필요 |
|---|---|---|
| 일일 | 운영 점검 | Check vibration levels, abnormal noise, cooling water flow, discharge temperature and pressure |
| 200 hours | 밸브 플레이트 검사 | 흡입/배출 밸브를 분리하여 탄소 침전물, 스프링 피로 또는 균열 여부를 점검하십시오. |
| 800 hours | 피스톤 링 마모 평가 | 링 홈 간극을 측정하고, 간극이 0.20mm를 초과하면 링을 교체하십시오. |
| 3,500 hours | 중간 정비 | 피스톤 링, 라이더 밴드 및 밸브 플레이트 어셈블리를 모두 교체하십시오. |
| 7,000 hours | 대대적인 개편 | Inspect crankshaft journals, measure main bearing clearances, replace bearings if >0.06 mm |
The oil-free design of the LW-25/16 significantly reduces maintenance complexity compared to lubricated high-pressure alternatives. There are no oil changes to schedule, no lubricating oil samples to analyze, no oil filter elements to replace, and no high-pressure oil separator cartridges to monitor. The primary consumable wear items are the PTFE 피스톤 링 및 라이더 밴드, which typically achieve 3,500–5,000 hours of service life under clean nitrogen conditions at high pressure. Valve plate assemblies generally achieve 2,000–3,500 hours before requiring refurbishment in high-pressure service.
규정 준수 및 안전 인증
The LW-25/16 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Section VIII Div.1, GB 150-2011, PED 2014/68/EU Module A (Category III)
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-25/16 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas where high-pressure nitrogen leakage could accumulate. Ventilation systems must be engineered to maintain ambient oxygen concentrations above 19.5% volume per OSHA 29 CFR 1910.146. Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic compressor isolation at 18.0% O₂ (hard shutdown). High-pressure nitrogen systems require additional safety measures including pressure relief valves, rupture discs, and automatic isolation valves on the discharge line. Personnel entry procedures into enclosed compressor rooms must include portable oxygen monitors and a buddy-system protocol. All high-pressure piping must be protected from mechanical damage and clearly labeled.
성과 및 효율성 분석
The LW-25/16 achieves a specific power consumption of approximately 8.00 kW per m³/min of nitrogen delivered at 1.60 MPa discharge pressure. This efficiency metric reflects the thermodynamic challenges inherent in compressing to elevated pressure ratios, yet remains competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated screw compressors operating at equivalent pressure ratios typically consume 8.5–9.5 kW/m³/min, while high-pressure diaphragm compressors (often selected for oil-free applications) can exceed 12 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the LW-25/16’s efficiency advantage versus less efficient alternatives yields approximately 100,000–240,000 kWh of annual energy savings. At an average industrial electricity tariff of $0.08/kWh, this represents $8,000–$19,200 in direct operating cost reduction per year. However, the primary economic driver for LW-25/16 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 further reduced by the absence of oil in the compression path. A typical oil-lubricated high-pressure compressor of this size requires coalescing filters, activated carbon adsorbers, oil monitoring instrumentation, and periodic oil changes that collectively add $15,000–$25,000 in annual operating costs. The LW-25/16’s oil-free design eliminates these expenses entirely while simultaneously improving reliability by removing the most common failure mode in high-pressure compressors: oil system contamination and degradation.
맞춤 제작 및 OEM 역량
We offer comprehensive customization options to adapt the LW-25/16 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 Safety Systems: Automatic pressure relief valves, rupture disc assemblies, high-pressure isolation valves, and emergency depressurization systems can be integrated into the discharge piping. All safety systems are designed to ASME BPVC Section VIII requirements.
- 환경 보호: C5-M marine-grade coating systems for coastal installations; tropicalized electrical components for ambient temperatures up to 55°C; and IP54-rated acoustic enclosures reducing noise emission from 87 dB(A) to 74 dB(A) at 1 meter.
- OEM 및 자체 브랜드: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators.
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 Inerting System Upgrade
고객: A major petrochemical complex in the Middle East operating polyethylene and polypropylene production units
도전: The client’s existing high-pressure nitrogen supply for reactor inerting and catalyst preservation was provided by two oil-lubricated reciprocating compressors (American brand, 20 years in service). Oil carryover into the nitrogen stream was contaminating Ziegler-Natta catalyst beds, reducing polymerization efficiency by 8–12% and requiring catalyst replacement every 14 months instead of the designed 24-month interval. The oil was also fouling reactor internals, necessitating unplanned shutdowns for cleaning. Annual losses from catalyst degradation and unplanned downtime exceeded $2.3 million.
해결책: 우리는 공급했습니다 LW-25/16 oil-free nitrogen compressor as the primary high-pressure nitrogen source, configured on a custom skid with integrated intercooler, aftercooler, high-pressure safety systems (relief valves, rupture discs, isolation valves), and a Siemens S7-1200 PLC control panel with SCADA integration. The 1.60 MPa discharge pressure met all reactor inerting and catalyst preservation requirements. A redundant standby unit was installed for 100% availability.
Quantified Results After 30 Months:
- 질소 오일 함량: 5.8 mg/m³에서 <0.01 mg/m³로 감소ISO 8573-1 클래스 0 인증을 획득했습니다.
- Catalyst replacement interval: Extended from 14 months to 28 months, saving $1.8 million/year in catalyst costs
- Polymerization efficiency: Improved by 9.5%, increasing annual production by 12,000 tonnes
- 예기치 않은 다운타임: Eliminated—zero oil-related shutdowns in 30 months
- Overall maintenance cost: Reduced by 38% through elimination of oil system repairs and catalyst-related cleaning
“The LW-25/16 has been transformative for our operations. The elimination of oil contamination has restored our catalyst performance to design levels and completely eliminated the unplanned shutdowns that were costing us millions. The payback period was under 12 months.” — Vice President of Operations, Petrochemical Complex
자주 묻는 질문 및 선택 가이드
관련 제품 및 솔루션
DW 시리즈 고압 질소 압축기
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 from 2 to 130 m³/min with two-stage and multi-stage configurations.
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 ultra-high-pressure gas filling, cylinder charging, and chemical process applications.
LW 시리즈 대용량 질소 압축기
극저온 공기분리장치(ASU) 백업, VPSA 부스팅 및 산업용 파이프라인 분배에 사용되는 고유량 무오일 피스톤 압축기(20~130m³/min). 토출 압력은 0.30~0.80MPa입니다.
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?
Our application engineers are standing by to evaluate your high-pressure nitrogen flow requirements, suction conditions, discharge pressure targets, and integration constraints. We provide complimentary technical proposals, foundation layout drawings, piping and instrumentation diagrams (P&IDs), high-pressure safety system designs, and detailed total cost of ownership (TCO) analyses within 48 hours of receiving your inquiry.
이메일: [email protected] 24시간 이내 답변드리겠습니다.
