LW-40/4 stikstofcompressor – olievrije N2-booster voor industriële gasdistributie onder middendruk

De LW-40/4 is een tweetraps, tweerijige olievrije zuigercompressor voor stikstof, ontworpen om 40 m³/min te leveren bij een persdruk van 0,40 MPa. Hij is speciaal ontwikkeld voor gebruik als back-up bij cryogene luchtscheiding, als stikstofbooster voor VPSA-systemen en voor distributienetwerken in middendrukpijpleidingen. De compressor is olievrij, geschikt voor continu gebruik en geoptimaliseerd voor 24/7 industrieel gebruik.

Productoverzicht

De LW-40/4 nitrogen compressor occupies a critical position in our oil-free piston compressor portfolio, bridging the gap between low-pressure nitrogen generation and medium-pressure distribution requirements. With a rated capacity of 40 m³/min en een afvoerdruk van 0.40 MPa, this unit is the workhorse of medium-scale cryogenic air separation plants, VPSA nitrogen booster stations, and industrial gas pipeline networks.

What distinguishes the LW-40/4 from conventional lubricated alternatives is its volledig olievrij compressiepad. The piston rings and rider bands are fabricated from self-lubricating PTFE composite materials that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This characteristic is indispensable for applications requiring ISO 8573-1 Class 0 certification, including food packaging nitrogen, pharmaceutical inerting, and semiconductor process gas supply.

De compressorarchitectuur volgt een tweetraps, twee rijen (二列二级) layout that divides the total pressure ratio across two compression cylinders. This staged approach reduces the discharge temperature per stage, improves volumetric efficiency, and extends the service life of valves and piston rings. Each compression stage is equipped with an independent intercooler, ensuring gas temperatures remain within safe operating envelopes even under sustained maximum load conditions.

Technical Specifications – LW-40/4

* Alle specificaties zijn gebaseerd op standaard referentieomstandigheden (ISO 1217, bijlage C). De werkelijke prestaties kunnen variëren afhankelijk van de hoogte van de locatie, de omgevingstemperatuur en de inlaatcondities.

Belangrijkste kenmerken en technische voordelen

1. Oil-Free PTFE Piston Ring Technology

The LW-40/4 utilizes a proprietary zelfsmurende zuigerveer- en geleidebandassemblage manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material combination achieves a coefficient of friction below 0.08 without any external lubrication, eliminating the risk of oil vapor carryover into the nitrogen product stream. For buyers operating in regulated industries, this translates directly to ISO 8573-1 Klasse 0-conformiteit without the capital and operating costs of downstream oil-filtration systems.

2. Staged Compression with Intercooling

De tweetraps compressiearchitectuur of the LW-40/4 is thermodynamically optimized for the 0.40 MPa discharge pressure target. By splitting the pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor achieves a lower mean effective temperature per stage. A dedicated shell-and-tube intercooler between stages removes the heat of compression, maintaining discharge temperatures below 155°C and preventing thermal degradation of the PTFE sealing elements. This thermal management strategy extends valve plate life by approximately 35% compared to single-stage designs operating at equivalent pressure ratios.

3. Robust Cast-Iron Frame with Force Balance

Het hoofdframe is gegoten uit GG25 grijs gietijzer (equivalent to ASTM A48 Class 30B) with integral cooling water passages. The two-row opposed-cylinder arrangement provides natural first-order force cancellation, reducing the unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs. This mechanical advantage allows the LW-40/4 to operate on a lighter foundation block (minimum 6 tonnes versus 10+ tonnes for single-row equivalents), reducing civil engineering costs and simplifying retrofit installations in existing compressor houses.

4. Standaard 380V industriële motoraandrijving

The LW-40/4 is driven by a 160 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. The standard 380V configuration eliminates the need for medium-voltage switchgear or step-down transformers, making this model particularly attractive for facilities with existing low-voltage distribution infrastructure. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied on a common skid.

Toepassingsscenario's

Cryogenic Air Separation Backup & Peak Shaving

In cryogenic ASU operations, the LW-40/4 serves as a reliable backup nitrogen booster or peak-shaving compressor. When the primary ASU experiences a cold box upset or requires maintenance, the LW-40/4 can maintain nitrogen supply to critical downstream consumers from liquid nitrogen storage vaporizers. Its 0.40 MPa discharge pressure is sufficient to feed medium-pressure distribution headers serving steel mill inerting, chemical reactor blanketing, and LNG plant purge gas systems. The oil-free design is particularly critical in backup scenarios where nitrogen purity cannot be compromised during primary system outages.

VPSA stikstofboosterstations

Vacuümdruk-swingadsorptie (VPSA) stikstofgeneratoren produceren gasvormige stikstof bij een druk die dicht bij de atmosferische druk ligt (0,05–0,10 MPa). LW-40/4 nitrogen booster compresses this low-pressure product to 0.40 MPa for distribution to point-of-use applications. The oil-free compression path is essential in VPSA service because any hydrocarbon contamination would poison the carbon molecular sieve adsorbent, permanently degrading the nitrogen generator’s separation efficiency and requiring costly adsorbent replacement.

Petrochemical Pipeline Nitrogen Injection

In petrochemical and refinery operations, nitrogen is injected into process pipelines and storage vessels to maintain inert atmospheres during startup, shutdown, and product changeover procedures. The LW-40/4’s 0.40 MPa discharge pressure provides adequate head to overcome pipeline friction losses over distances up to 2 km, making it suitable for centralized nitrogen supply to multiple process units. The continuous-duty rating ensures uninterrupted nitrogen availability during extended maintenance campaigns that may last several weeks.

Food & Beverage Modified Atmosphere Packaging

Large-scale food packaging facilities require high-flow nitrogen for Verpakking onder gemodificeerde atmosfeer (MAP) and controlled atmosphere storage. The LW-40/4’s 40 m³/min capacity can simultaneously supply multiple high-speed packaging lines, while its oil-free certification ensures compliance with FDA 21 CFR 173.310 (food-grade nitrogen) and EU Regulation 231/2012. The absence of oil contamination eliminates the risk of off-flavors, rancidity, or product discoloration that can occur when lubricated compressors are used in food-contact applications.

Materiaal en constructie

Every component of the LW-40/4 is selected for compatibility with nitrogen service, corrosion resistance, and long-term mechanical integrity:

All pressure vessels are designed and fabricated in accordance with ASME BPVC Sectie VIII Divisie 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic testing (RT) per ASME Section V, Article 2, and each completed vessel is subjected to a hydrostatic pressure test at 1.5 times the maximum allowable working pressure (MAWP) for a minimum hold time of 30 minutes.

Installatie- en onderhoudsrichtlijnen

Foundation & Mounting

The LW-40/4 has a dry weight of 4.50 tonnes and a center of gravity approximately 850 mm above the baseplate. Due to the two-row opposed-cylinder design, the unbalanced forces are minimal, allowing installation on a reinforced concrete inertia block of 6–8 tonnes. The block should be mounted on vibration isolation pads (natural frequency 6–8 Hz) to prevent vibration transmission to adjacent structures. 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.

Cooling Water Requirements

The LW-40/4 requires approximately 38 m³/h of cooling water at an inlet temperature not exceeding 32°C. The cooling water system must supply the cylinder jackets, intercooler, and aftercooler in parallel circuits. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS304 tube corrosion), and suspended solids < 30 mg/L. For sites with marginal water quality, a closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended.

Preventief onderhoudsschema

A key economic advantage of the LW-40/4 is the absence of lubricating oil in the compression path. Unlike oil-lubricated compressors that require quarterly oil changes, monthly oil analysis, and annual separator element replacement, the LW-40/4 eliminates these consumables entirely. The only recurring wear items are the PTFE piston rings and rider bands, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions.

Certificeringen voor naleving en veiligheid

The LW-40/4 nitrogen compressor is designed, manufactured, and tested to meet the following international standards and regulatory frameworks:

Prestatie- en efficiëntieanalyse

The LW-40/4 achieves a specific power consumption of approximately 4.00 kW per m³/min of nitrogen at 0.40 MPa discharge pressure. This efficiency metric positions the unit in the upper tier of oil-free piston compressors within the 30–50 m³/min capacity range. For context, typical oil-lubricated screw compressors operating at equivalent pressure ratios consume 4.4–4.9 kW/m³/min, while legacy single-stage piston designs may exceed 5.2 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the LW-40/4’s efficiency advantage yields approximately 128,000–288,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this translates to $10,240–$23,040 in direct operating cost reduction per year. When combined with the elimination of oil-related consumables (lubricating oil, filter elements, separator cartridges, waste oil disposal), the totale eigendomskosten voor stikstofcompressie wordt naar schatting met 25–35% verminderd gedurende een operationele levensduur van 10 jaar.

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 requires coalescing filters, activated carbon adsorbers, and monitoring instrumentation that collectively consume 3–5% of the compressor’s power output. The LW-40/4’s oil-free design removes this parasitic load entirely.

Mogelijkheden voor maatwerk en OEM-productie

We offer comprehensive customization options to adapt the LW-40/4 to specific site conditions, integration requirements, and end-user specifications:

• Kant-en-klare pakketten op een frame: 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.
• Configuraties van gevaarlijke zones: Motor- en elektrische behuizingen die voldoen aan de ATEX Zone 2- en IECEx-normen zijn beschikbaar voor installaties in petrochemische installaties waar incidenteel explosieve atmosferen kunnen voorkomen. Gasdetectie en automatische ventilatievergrendelingen kunnen in het besturingssysteem worden geïntegreerd.
• Geavanceerde procesbesturing: Optioneel verkrijgbaar: Siemens S7-1200 of Allen-Bradley CompactLogix PLC met 10-inch HMI-touchscreen, bewaking op afstand via Modbus TCP/IP of OPC-UA, en naadloze DCS/SCADA-integratie. Automatische laad-/losregeling en compatibiliteit met frequentieregelaars (VFD's) optimaliseren de efficiëntie bij deellast.
• Milieubescherming: C5-M coatingsystemen van maritieme kwaliteit voor installaties aan de kust of op zee; tropische elektrische componenten voor omgevingstemperaturen tot 55 °C; en IP54-gecertificeerde geluidsisolerende behuizingen die de geluidsemissie op 1 meter afstand reduceren van 85 dB(A) tot 72 dB(A).
• OEM & Private Label: Aangepaste lakkleuren, naamplaatjes met logo en documentatiepakketten zijn beschikbaar voor systeemintegratoren en distributeurs van gasapparatuur. Technische handleidingen, onderdelenlijsten en onderhoudsprocedures kunnen in lokale talen worden geleverd.

Aangepaste configuraties zijn beschikbaar via Minimale bestelhoeveelheid: 1 stukDe technische beoordeling en het opstellen van een voorstel duren doorgaans 5-7 werkdagen. De levertijd voor prototypes varieert van 12 tot 14 weken; herhaalbestellingen worden binnen 8-10 weken na orderbevestiging geleverd.

Case Study: VPSA Nitrogen Booster Upgrade in Southeast Asia

Cliënt: A major industrial gas supplier operating a VPSA nitrogen generation facility in Vietnam

Uitdaging: The client’s existing oil-lubricated nitrogen booster (European brand, 15 years in service) was experiencing progressive oil carryover into the nitrogen product. Oil contamination levels reached 2.8 mg/m³, exceeding the 0.1 mg/m³ limit specified by their food packaging customers. The oil was also degrading the activated carbon final-polishing bed, requiring replacement every 8 months instead of the designed 24-month interval.

Oplossing: Wij leverden een LW-40/4 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel. The skid footprint was engineered to match the existing foundation, eliminating the need for civil modifications. A 2 m³ surge vessel was added upstream to dampen pressure pulsations from the VPSA adsorption cycle.

Gekwantificeerde resultaten na 24 maanden:

• Stikstofgehalte van de olie: Reduced from 2.8 mg/m³ to <0.01 mg/m³, waarbij de ISO 8573-1 Klasse 0-certificering is behaald.
• Interval voor vervanging van het actieve koolbed: Extended from 8 months to 30 monthswaardoor jaarlijks $12.000 aan verbruiksartikelen wordt bespaard.
• Totale onderhoudskosten: Decreased by 38% door het vervallen van olieverversingen, filtervervangingen en revisies van de separator.
• Energieverbruik: Improved by 7.2% versus the replaced unit, equivalent to $15,600/year savings at local electricity rates
• Ongeplande downtime: Nul gebeurtenissen in 24 maanden ononderbroken bedrijf

“The LW-40/4 eliminated our oil contamination problem completely. Our food packaging customers no longer report quality issues, and our maintenance team has cut their service time by nearly half. The payback period was under 18 months.” — Facility Operations Director

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Voor een uitgebreid overzicht van onze industriële stikstofcompressor product range, including oil-free oxygen compressors, hydrogen compressors, carbon dioxide compressors, and custom-engineered specialty gas solutions, please contact our application engineering team or browse our online product catalog.

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