설명
LW-52/3 질소 압축기 – 산업용 공기 분리용 고용량 무오일 N2 부스터
Delivering 52 m³/min at 0.30 MPa discharge pressure, the LW-52/3 is a two-stage, two-row oil-free piston nitrogen compressor engineered for large-scale cryogenic air separation and VPSA nitrogen generation plants. Zero lubricant contamination, continuous-duty rated, and built for 24/7 industrial reliability.
제품 개요
그만큼 LW-52/3 nitrogen compressor is a flagship model in our oil-free piston compressor lineup, purpose-built for nitrogen boosting duties in cryogenic air separation and vacuum pressure swing adsorption (VPSA) systems. With a massive capacity of 52 m³/min and a discharge pressure of 0.30 MPa, this unit bridges the gap between primary air separation and downstream nitrogen distribution networks.
Unlike lubricated alternatives that risk oil contamination in high-purity nitrogen streams, the LW-52/3 operates on a completely oil-free lubrication system. This design eliminates the need for downstream oil-removal filtration, reduces maintenance complexity, and ensures compliance with stringent purity requirements for food packaging, pharmaceutical blanketing, and electronics manufacturing.
The compressor features a 2단 2열(two 列 级) configuration that optimizes thermodynamic efficiency across the pressure ratio. Each stage is independently cooled, maintaining discharge temperatures within safe operating limits even during continuous 24/7 operation. The robust cast-iron frame and precision-machined crankshaft assembly are rated for over 80,000 hours of service life under standard maintenance protocols.
Technical Specifications – LW-52/3
| 매개변수 | 값 | 단위 |
|---|---|---|
| 모델 | LW-52/3 | – |
| 무늬 | 2단, 2열(two 列 级) | – |
| 용량 | 52 | m³/min |
| 토출 압력 | 0.30 | MPa |
| 압축기 크기 (길이 × 너비 × 높이) | 2995 × 1600 × 2170 | mm |
| 무게 | 4.28 | 티 |
| 힘 | 220 | 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. Oil-Free Piston Technology
The LW-52/3 employs a self-lubricating piston ring and rider band system constructed from advanced PTFE composite materials. This eliminates the risk of hydrocarbon contamination in the nitrogen stream—a critical requirement for food-grade nitrogen (ISO 8573-1 Class 0 oil content) and pharmaceutical applications. The oil-free design also reduces the total cost of ownership by eliminating oil changes, filter replacements, and oil-separation equipment.
2. Two-Stage Thermodynamic Optimization
With a two-stage compression arrangement, the LW-52/3 splits the overall pressure ratio across two cylinders, reducing the discharge temperature per stage and improving volumetric efficiency. Inter-stage cooling is provided by a dedicated shell-and-tube heat exchanger, maintaining gas temperatures below 160°C even at maximum continuous load. This thermal management extends valve life and reduces the risk of polymerization in nitrogen streams containing trace oxygen.
3. Heavy-Duty Frame & Crankshaft
The compressor block is cast from GG25 회주철 with integral cooling water jackets. The forged steel crankshaft is dynamically balanced to ISO 1940 G2.5 standards, minimizing vibration transmission to the foundation. The two-row configuration provides inherent force balance, reducing the need for massive concrete inertia blocks—an important consideration for retrofit installations in existing air separation plants.
4. Flexible Voltage Configuration
The 220 kW drive motor is available in 380V, 6kV 또는 10kV configurations, allowing direct integration into medium-voltage industrial distribution networks without additional step-down transformers. This flexibility is particularly valuable for large-scale air separation facilities where 6kV or 10kV bus systems are standard, reducing electrical infrastructure costs and improving overall energy efficiency.
응용 시나리오
Cryogenic Air Separation Plants
In cryogenic ASU (Air Separation Unit) facilities, the LW-52/3 serves as the primary nitrogen booster between the cold box and the gaseous nitrogen distribution header. Its 52 m³/min capacity matches the output of medium-scale ASUs producing 1,000–2,000 Nm³/h of gaseous nitrogen. The 0.30 MPa discharge pressure is optimized for pipeline distribution to downstream consumers such as steel mills, chemical plants, and LNG liquefaction facilities.
VPSA Nitrogen Generation Systems
을 위한 VPSA nitrogen generator installations, the LW-52/3 compresses the low-pressure nitrogen product (typically 0.05–0.10 MPa) to distribution pressure. The oil-free design is essential here because VPSA systems produce nitrogen at relatively high purity (99.5–99.9%), and any oil contamination would degrade the product quality and damage downstream molecular sieves.
Petrochemical & Refinery Blanketing
Refinery tank farms and petrochemical storage facilities require large volumes of nitrogen for tank blanketing and inerting to prevent explosive vapor formation. The LW-52/3’s continuous-duty rating and high flow capacity make it ideal for serving multiple storage tanks simultaneously through a centralized nitrogen header. The 0.30 MPa pressure is sufficient to overcome tank pressure relief valve settings and maintain positive pressure during product withdrawal cycles.
Food Packaging & Modified Atmosphere
In food packaging lines using modified atmosphere packaging (MAP), nitrogen displaces oxygen to extend shelf life. The LW-52/3’s oil-free certification ensures compliance with FDA 21 CFR and EU 1935/2004 food contact regulations. The high flow rate supports multiple packaging machines operating in parallel, making it suitable for large-scale snack food, dairy, and ready-meal production facilities.
자재 및 시공
The LW-52/3 is built from materials selected for compatibility with nitrogen service and long-term industrial durability:
| 요소 | 재료 | 사양 |
|---|---|---|
| 실린더 블록 | 회색 주철 | GG25 / HT250 |
| 크랭크 샤프트 | 단조 합금강 | 42CrMo4, Q&T |
| 피스톤 링 | PTFE 복합재 | Self-lubricating, oil-free |
| 밸브 플레이트 | 스테인리스 스틸 | SS304 / SS316 |
| Cooling Water Jackets | Cast Iron with Epoxy Lining | Corrosion-resistant |
| 인터쿨러 | Carbon Steel Shell / SS Tubes | ASME VIII Div.1 |
All pressure-bearing components are designed to ASME BPVC 섹션 VIII 부문 1 or equivalent Chinese GB 150 standards. Weld joints undergo 100% radiographic inspection (RT) and hydrostatic testing at 1.5× design pressure before shipment.
설치 및 유지 관리 지침
Foundation Requirements
The LW-52/3 weighs 4.28 tonnes and generates minimal unbalanced forces due to its two-row opposed-cylinder design. A reinforced concrete inertia block of minimum 8 tonnes is recommended, mounted on vibration isolation pads (natural frequency < 8 Hz). The foundation must support the full weight plus a dynamic factor of 1.5. Allow minimum 1.5m clearance on all sides for maintenance access.
Cooling Water System
Cooling water flow requirement is approximately 45 m³/h at 32°C inlet temperature. Water quality should meet industrial standards: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, suspended solids < 50 mg/L. A closed-loop cooling tower with side-stream filtration is recommended for tropical climates to prevent scale formation in intercooler tubes.
Maintenance Schedule
| 간격 | 서비스 항목 | Action |
|---|---|---|
| 일일 | Visual Inspection | Check oil levels, leaks, abnormal noise |
| 250시간 | Filter & Valve Check | Inspect suction/discharge valves for carbon buildup |
| 1,000시간 | Piston Ring Inspection | Measure ring groove clearance, replace if > 0.3mm |
| 4,000시간 | 대대적인 개편 | Replace piston rings, rider bands, valve plates |
| 8,000시간 | Crankshaft & Bearing | Inspect main bearings, measure crankshaft runout |
Because the LW-52/3 is oil-free, the maintenance burden is significantly lower than lubricated alternatives. There are no oil filters to replace, no oil analysis to perform, and no oil separator elements to monitor. The primary wear items are the PTFE 피스톤 링 및 라이더 밴드, which typically last 4,000–6,000 hours depending on operating conditions.
규정 준수 및 안전 인증
The LW-52/3 nitrogen compressor meets or exceeds the following international standards and regulatory requirements:
ASME BPVC Section VIII Div.1, GB 150, PED 2014/68/EU (Module A)
IEC 60034-1 (Rotating Machines), IEC 60204-1 (Machine Safety)
ISO 8573-1 Class 0 (Oil Content), TÜV Rheinland Tested
ISO 9001:2015, ISO 14001:2015
⚠️ Safety Notice
Nitrogen is an asphyxiant gas. All LW-52/3 installations must include oxygen deficiency monitoring in enclosed compressor rooms. Ventilation rates must maintain oxygen levels above 19.5% per OSHA 29 CFR 1910.146. Emergency shutdown systems should be tied to O₂ sensors with automatic alarm at 19.5% and hard shutdown at 18.0%.
성과 및 효율성 분석
The LW-52/3 achieves a specific power consumption of approximately 4.23 kW per m³/min of nitrogen delivered at 0.30 MPa. This places it in the top quartile of efficiency for oil-free piston compressors in this capacity range. For comparison, typical lubricated screw compressors in similar applications consume 4.5–5.0 kW/m³/min, while older single-stage piston designs may exceed 5.5 kW/m³/min.
Over an 8,000-hour annual operating cycle, the LW-52/3’s efficiency advantage translates to approximately 180,000–350,000 kWh of energy savings versus less efficient alternatives. At an industrial electricity rate of $0.08/kWh, this represents $14,400–$28,000 in annual operating cost reduction—often recovering the incremental capital investment within 2–3 years.
그만큼 질소 압축의 총 소유 비용 is further reduced by the elimination of oil-related consumables. A typical lubricated compressor of this size consumes 200–400 liters of lubricating oil annually, plus oil filter elements, separator cartridges, and waste oil disposal costs. The LW-52/3’s oil-free design eliminates these recurring expenses entirely.
맞춤 제작 및 OEM 역량
Beyond the standard LW-52/3 configuration, we offer extensive customization to match specific plant requirements:
- Skid-Mounted Packages: Complete compressor, motor, cooler, and instrumentation pre-mounted on a structural steel skid with lifting lugs. Reduces field installation time by 60%.
- Explosion-Proof Configurations: ATEX/IECEx certified motor and electrical enclosures for Zone 2 hazardous area installations in petrochemical facilities.
- PLC Control Integration: Siemens S7-1200 or Allen-Bradley CompactLogix PLC with HMI touchscreen, remote monitoring via Modbus TCP/IP, and integration with plant DCS/SCADA.
- Special Coatings: C5-M marine-grade paint system for coastal or offshore installations; epoxy internal coatings for corrosive environments.
- Sound Enclosures: Acoustic enclosures reducing noise levels from 85 dB(A) to 72 dB(A) at 1m distance, suitable for indoor installations without dedicated compressor houses.
Minimum order quantity for customized configurations is 1 unit. Prototype delivery time is 12–14 weeks; serial production orders deliver in 8–10 weeks from order confirmation. OEM branding and private labeling are available for qualified distributors and system integrators.
Case Study: Cryogenic ASU Nitrogen Booster Retrofit
고객: A leading industrial gas supplier in Southeast Asia
도전: The client’s existing lubricated nitrogen booster (competitor brand, 12 years in service) was experiencing frequent oil carryover into the nitrogen product stream, causing contamination of downstream cryogenic storage and customer complaints from food packaging clients.
해결책: 우리는 공급했습니다 LW-52/3 oil-free nitrogen compressor as a direct replacement, mounted on a custom skid with integrated intercooler, aftercooler, and PLC control panel. The footprint was designed to match the existing foundation, minimizing civil works.
Results:
- Oil content in nitrogen product: Reduced from 3.2 mg/m³ to <0.01 mg/m³ (ISO 8573-1 Class 0)
- 연간 유지 관리 비용: Reduced by 42% (elimination of oil changes, filter replacements, separator overhauls)
- 에너지 소비량: Reduced by 8.5% versus the replaced unit, saving approximately $18,000/year
- Downtime: Zero unplanned outages in the first 18 months of operation
“The switch to the oil-free LW-52/3 completely solved our nitrogen purity issues. Our food packaging customers have noticed the difference in product consistency, and our maintenance team appreciates the simplified service schedule.” — Plant Engineering Manager
자주 묻는 질문 및 선택 가이드
관련 제품 및 솔루션
DW Series Nitrogen Compressors
Higher pressure range (0.40–2.00 MPa) for nitrogen injection, pipeline boosting, and high-pressure blanketing applications. Capacities from 2 to 130 m³/min.
ZW Series Oil-Free Compressors
Vertical, multi-stage oil-free compressors for oxygen, nitrogen, and specialty gases. Discharge pressures up to 9.00 MPa for high-pressure gas filling and chemical synthesis.
MW Series Medium Pressure Compressors
Medium-pressure oil-free compressors (1.0–4.0 MPa) for nitrogen recycle, gas liquefaction, and process gas compression in petrochemical plants.
For a complete overview of our 산업용 질소 압축기 portfolio, including oil-free oxygen compressors, hydrogen compressors, and specialty gas solutions, visit our product catalog or contact our engineering team for a customized selection.
Ready to Upgrade Your Nitrogen Compression System?
Our application engineers are available to review your nitrogen flow requirements, inlet conditions, and discharge pressure specifications. We provide free technical proposals, layout drawings, and TCO analysis within 48 hours.
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