Kompresor azotowy LW-18/12 – średnioprzepływowy, wysokociśnieniowy, bezolejowy wzmacniacz N2 do wymagających zastosowań przemysłowych

Zaprojektowana do dostarczania 18 m³/min przy ciśnieniu wylotowym 1,20 MPa, sprężarka LW-18/12 to dwustopniowa, dwurzędowa, bezolejowa tłokowa sprężarka azotu, zaprojektowana specjalnie do wysokociśnieniowego wtrysku azotu, syntezy chemicznej i dystrybucji specjalistycznych gazów przemysłowych, gdzie wysokie ciśnienie i bezkompromisowa czystość idą w parze. Urządzenie jest przystosowane do pracy ciągłej i zoptymalizowane do pracy 24/7 w najbardziej wymagających warunkach.

Przegląd produktu

Ten LW-18/12 nitrogen compressor occupies a specialized niche within our oil-free piston compressor portfolio, engineered for applications where elevated discharge pressure takes precedence over absolute flow volume. With a rated capacity of 18 m³/min i wyjątkowy 1.20 MPa discharge pressure, this unit bridges the gap between standard medium-pressure nitrogen boosters and the ultra-high-pressure domain of multi-stage specialty gas compressors.

What distinguishes the LW-18/12 from conventional high-pressure alternatives is its całkowicie bezolejowy mechanizm kompresji utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, making the unit immediately suitable for high-purity chemical synthesis, pharmaceutical-grade nitrogen injection, and electronics-grade process gas supply without requiring additional downstream purification stages. The oil-free certification is particularly critical at 1.20 MPa because oil contamination at elevated pressure becomes exponentially more difficult and expensive to remove.

Its dwustopniowy, dwurzędowy (二列二级) configuration is thermodynamically optimized for the high pressure ratio demanded by 1.20 MPa discharge. The staged compression with inter-stage cooling limits the discharge temperature of each cylinder to safe operating envelopes, preserving the integrity of the PTFE sealing elements and extending valve service life. The robust construction—2632 × 1550 × 2332 mm I 3.00 tonnes—reflects the heavy-duty engineering required to sustain high-pressure operation while maintaining the compact footprint characteristic of the LW series.

Technical Specifications – LW-18/12

* Wszystkie parametry podano w standardowych warunkach odniesienia (ISO 1217, załącznik C). Rzeczywista wydajność może się różnić w zależności od wysokości nad poziomem morza, temperatury otoczenia i warunków na wlocie.

Kluczowe cechy i zalety inżynieryjne

1. Technologia uszczelnień PTFE bez oleju pod wysokim ciśnieniem

The LW-18/12 employs a specialized samosmarujący układ pierścieni tłokowych i taśmy nośnej manufactured from high-performance PTFE composites reinforced with glass fiber, bronze particulates, and molybdenum disulfide. This advanced formulation achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover risk even at the elevated temperatures associated with 1.20 MPa discharge pressure. For operators in chemical synthesis and pharmaceutical manufacturing, this delivers natywna zgodność z normą ISO 8573-1 Klasa 0 without the capital expense, energy penalty, or maintenance burden of high-pressure oil-removal systems that would otherwise be mandatory at this pressure level.

2. Dwustopniowa kompresja dla ekstremalnych współczynników ciśnień

Ten architektura kompresji dwuetapowej of the LW-18/12 is thermodynamically critical for achieving the 1.20 MPa discharge pressure from typical nitrogen inlet conditions (0.05–0.10 MPa). By dividing the extreme pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor limits the discharge temperature of each stage to below 160°C. A high-efficiency shell-and-tube intercooler between stages removes the heat of compression, preventing thermal degradation of the PTFE sealing elements and extending valve plate service life by approximately 50% compared to single-stage designs attempting equivalent pressure ratios. The staged approach also improves volumetric efficiency, delivering more nitrogen per unit of power consumed.

3. Reinforced High-Pressure Cylinder Construction

The high-pressure cylinder of the LW-18/12 is constructed from Żeliwo szare GG30 with thicker wall sections and reinforced head bolts compared to standard-pressure models. The cylinder head features a multi-layer gasket system with stainless steel fire rings to prevent blow-by at 1.20 MPa. The valve cage assemblies are fabricated from SS316L forged bar stock rather than castings, eliminating porosity risks that could lead to catastrophic failure under high cyclic pressure loading. All high-pressure components are subjected to 100% magnetic particle inspection (MT) and ultrasonic testing (UT) to detect subsurface defects before assembly.

4. Standardowy przemysłowy napęd silnikowy 380 V

The LW-18/12 is driven by a 160 kW, 380V, 50Hz three-phase induction motor rated to IEC 60034-1 efficiency class IE3. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage infrastructure, making this model accessible to facilities that may not have 6kV or 10kV bus systems. The 160 kW power rating is optimized for the 18 m³/min flow and 1.20 MPa pressure, achieving a favorable balance between capital cost and operating efficiency for medium-flow high-pressure applications.

Scenariusze zastosowań

High-Pressure Chemical Synthesis & Reactor Inerting

In chemical manufacturing facilities, the LW-18/12 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, and emergency nitrogen injection into process vessels operating at elevated pressures. The 1.20 MPa discharge pressure is sufficient to overcome the operating pressure of typical chemical reactors and distillation columns, allowing direct nitrogen injection without intermediate pressure boosting. The oil-free design is absolutely critical in chemical synthesis because even trace oil contamination can poison precious metal catalysts, initiate unwanted side reactions, or contaminate high-purity product streams. The 18 m³/min capacity supports multiple reactor systems operating in parallel within a medium-scale chemical plant.

Pharmaceutical High-Pressure Nitrogen Injection

Pharmaceutical manufacturing facilities require high-purity nitrogen for sterile vessel inerting, lyophilization (freeze-drying) chamber pressurization, and aseptic filling line purging. Ten LW-18/12 high-pressure nitrogen compressor delivers the 1.20 MPa pressure required for lyophilization chamber operation while maintaining ISO 8573-1 Class 0 oil-free certification. The 18 m³/min capacity can simultaneously supply multiple lyophilizers, sterile holding tanks, and filling lines within a medium-scale pharmaceutical facility. The oil-free design eliminates the risk of product contamination that could trigger FDA regulatory action or batch rejection.

Electronics High-Pressure Process Gas Supply

In semiconductor fabrication and flat-panel display manufacturing, nitrogen is used for high-pressure wafer handling, chamber purge, and chemical vapor deposition (CVD) process support. The LW-18/12’s 1.20 MPa discharge pressure is sufficient for high-purity nitrogen distribution to process tools operating at elevated pressures. The oil-free certification is non-negotiable in electronics manufacturing because even sub-ppm oil contamination can cause wafer defects, reduce device yield, and compromise the performance of sensitive optical coatings. The 18 m³/min capacity supports a cluster of process tools within a cleanroom bay.

Nitrogen Cylinder Filling & Gas Distribution

Industrial gas distributors and cylinder filling stations require high-pressure nitrogen compressors to fill standard industrial gas cylinders (typically 15 MPa at 20°C) from lower-pressure sources such as liquid nitrogen vaporizers or membrane generators. The LW-18/12 serves as the first-stage booster in a multi-stage filling system, compressing nitrogen from 0.10 MPa to 1.20 MPa for subsequent high-pressure compression to cylinder pressure. The oil-free design ensures that filled cylinders meet the purity specifications of medical, food-grade, and electronic-grade nitrogen markets without requiring cylinder evacuation and re-purging due to oil contamination.

Materiały i budownictwo

The LW-18/12 is constructed from premium materials specifically selected for high-pressure nitrogen service, corrosion resistance, and extended operational life under demanding conditions:

Wszystkie elementy przenoszące ciśnienie są projektowane i wytwarzane w ścisłej zgodności z ASME BPVC Sekcja VIII Dział 1 or Chinese GB 150 standards. 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 components receive additional magnetic particle inspection (MT) and ultrasonic testing (UT) to ensure zero defect tolerance.

Wytyczne dotyczące instalacji i konserwacji

Wymagania dotyczące fundamentów i konstrukcji

The LW-18/12 has a dry weight of 3.00 tonnes and a center of gravity approximately 800 mm above the baseplate. The two-row opposed-cylinder design provides inherent force balance, allowing installation on a reinforced concrete pad of 5–6 tonnes. The pad should be mounted on elastomeric vibration isolators (natural frequency 8–12 Hz) to prevent vibration transmission to sensitive adjacent equipment such as analytical instruments or precision manufacturing tools. Minimum clearance requirements: 1.2 m on the non-drive side for valve access, 1.0 m on the drive side for motor maintenance, and 1.5 m overhead for crane access during major overhauls.

Projektowanie układu chłodzenia wodnego

Zapotrzebowanie na wodę chłodzącą wynosi około 22 m³/godz. 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 high-pressure coolers), 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 heat exchangers.

Harmonogram konserwacji zapobiegawczej

The oil-free design of the LW-18/12 dramatically simplifies maintenance 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 Pierścienie tłokowe i opaski zaciskowe PTFE, which typically achieve 3,500–5,500 hours of service life under clean nitrogen conditions at 1.20 MPa. The high-pressure valve assemblies require more frequent inspection than low-pressure models due to the increased mechanical stress on valve plates and springs.

Certyfikaty zgodności i bezpieczeństwa

The LW-18/12 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Analiza wydajności i efektywności

The LW-18/12 achieves a specific power consumption of approximately 8.89 kW per m³/min of nitrogen delivered at 1.20 MPa discharge pressure. This specific power is higher than lower-pressure models due to the thermodynamic penalty associated with elevated pressure ratios, but it remains competitive within the high-pressure oil-free piston compressor segment. For context, oil-lubricated screw compressors operating at equivalent pressure ratios typically consume 9.5–10.5 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-18/12’s efficiency advantage versus less efficient alternatives yields approximately 72 000–144 000 kWh rocznych oszczędności energii. At an average industrial electricity tariff of $0.08/kWh, this represents $5,760–$11,520 in direct operating cost reduction per year. However, the primary economic driver for LW-18/12 selection is typically the elimination of oil-related consumables and the avoidance of high-pressure oil-removal equipment zamiast marginalnych oszczędności energii.

At 1.20 MPa, the cost and complexity of downstream oil-removal equipment becomes prohibitive. A typical oil-lubricated compressor at this pressure would require multiple stages of coalescing filtration, activated carbon adsorption, and continuous oil monitoring instrumentation, collectively consuming 5–8% of the compressor’s power output and requiring annual maintenance expenditure of $8,000–$15,000. The LW-18/12’s oil-free design removes this parasitic load and maintenance burden entirely, delivering a significantly lower total cost of ownership for high-pressure nitrogen compression.

Możliwości personalizacji i OEM

We provide comprehensive customization options to adapt the LW-18/12 to specific high-pressure application requirements, site conditions, and integration constraints:

• Pakiety „pod klucz” montowane na płozach: 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 high-pressure systems reduces field commissioning time and minimizes startup risks.
• Konfiguracje stref niebezpiecznych: ATEX Zone 2 and IECEx compliant motor and electrical enclosures are available for installations in chemical processing facilities where explosive atmospheres may occasionally be present. Integrated gas detection and automatic ventilation interlocks can be incorporated into the control system.
• Zaawansowana kontrola procesów: 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 pressure regulation optimize operation for variable demand profiles.
• Systemy bezpieczeństwa wysokociśnieniowego: Redundant high-pressure relief valves, rupture disc assemblies, and automatic isolation valves can be integrated to meet specific safety integrity level (SIL) requirements. Pressure transmitters with 4–20 mA output provide continuous monitoring of discharge pressure.
• Ochrona środowiska: 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 from 84 dB(A) to 70 dB(A) at 1 meter.
• OEM i marka własna: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators serving specialized industrial markets.

Dostępne są konfiguracje niestandardowe MOQ 1 jednostkaPrzegląd techniczny i wygenerowanie oferty zazwyczaj zajmują od 5 do 7 dni roboczych. Standardowy czas dostawy wynosi 12–14 tygodni; zamówienia powtarzalne są realizowane w ciągu 8–10 tygodni od potwierdzenia zamówienia.

Case Study: Pharmaceutical Lyophilization Nitrogen Supply Upgrade

Klient: A pharmaceutical manufacturing facility in Europe specializing in injectable biologics and vaccines

Wyzwanie: The facility’s lyophilization (freeze-drying) chambers required high-pressure nitrogen at 1.00–1.20 MPa for chamber pressurization and stopper insertion. The existing supply relied on high-pressure nitrogen cylinders delivered weekly, with costs exceeding €180,000/year and frequent supply disruptions during winter weather. The facility also faced regulatory pressure to reduce its carbon footprint from cylinder transportation and vaporization losses.

Rozwiązanie: Dostarczyliśmy LW-18/12 oil-free nitrogen compressor paired with a small VPSA nitrogen generator (99.9% purity, 20 m³/min) on a common skid. The LW-18/12 compresses the VPSA product from 0.08 MPa to 1.20 MPa, feeding the lyophilization chamber nitrogen header directly. The oil-free design ensured compliance with EU GMP Annex 1 (sterile manufacturing) requirements for oil-free process gases. A 2 m³ high-pressure buffer vessel was installed downstream to absorb demand spikes during chamber cycling.

Wyniki ilościowe po 18 miesiącach:

• Koszt dostawy azotu: Obniżka o 58% (€180,000 to €75,600/year) versus cylinder supply
• Supply reliability: 100% on-site generation, zero weather-related disruptions
• Czystość azotu: Konsekwentnie >99,9% with oil content <0.01 mg/m³, exceeding GMP requirements
• Carbon footprint: Zredukowano o 65% through elimination of cylinder transportation and vaporization losses
• Maintenance: One scheduled service per year (4,000-hour interval), versus weekly cylinder handling
• Okres zwrotu: 2,1 roku based on gas cost savings alone

“The LW-18/12 has eliminated our dependency on cylinder deliveries and given us complete control over our nitrogen supply. The oil-free certification was critical for our GMP compliance, and the cost savings have exceeded our projections. Our sustainability team is particularly pleased with the carbon footprint reduction.” — Director of Engineering, Pharmaceutical Manufacturing

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