LW-9.5/30 Nitrogen Compressor – Oil-Free N2 Booster for 3.00 MPa High-Pressure Process Applications

Компрессор LW-9.5/30, разработанный для обеспечения производительности 9,5 м³/мин при давлении на выходе 3,00 МПа, представляет собой двухступенчатый трехрядный безмасляный поршневой азотный компрессор, предназначенный для впрыска азота под высоким давлением, работы в качестве бустера для сжижения газа и в сложных нефтехимических процессах. Он отличается нулевым загрязнением маслом, рассчитан на непрерывную работу и рассчитан на круглосуточную промышленную надежность при повышенном давлении.

Обзор продукта

Он LW-9.5/30 nitrogen compressor occupies a critical position in our oil-free piston compressor lineup, engineered specifically for applications demanding both substantial flow capacity and high discharge pressure. With a rated capacity of 9.5 m³/min и исключительный Давление на выходе 3,00 МПа, this unit addresses the most demanding high-pressure nitrogen boosting requirements in industrial gas processing, chemical synthesis, and petrochemical operations.

What distinguishes the LW-9.5/30 from conventional alternatives is its полностью безмасляный компрессионный канал. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants. This intrinsic oil-free characteristic ensures the nitrogen product stream remains completely uncontaminated, achieving Сертификация ISO 8573-1 Класс 0 natively. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is magnified compared to low-pressure applications, making the oil-free design not merely advantageous but absolutely essential for process integrity.

В конструкции компрессора используется двухступенчатый, трехрядный (二列三级) configuration that optimally distributes the substantial pressure ratio across multiple compression stages. This multi-stage approach is thermodynamically essential for managing the thermal loads associated with 3.00 MPa discharge pressure while preserving the integrity of the PTFE sealing elements. Each stage features an independent intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-capacity operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120 000 часов в соответствии со стандартными протоколами технического обслуживания.

Technical Specifications – LW-9.5/30

* Все технические характеристики указаны для стандартных эталонных условий (ISO 1217, Приложение C). Фактические характеристики могут отличаться в зависимости от высоты расположения объекта, температуры окружающей среды и условий на входе.

Основные характеристики и инженерные преимущества

1. Multi-Stage Compression for Extreme Pressure Ratios

Он two-stage, three-row (二列三级) architecture of the LW-9.5/30 is thermodynamically essential for achieving the 3.00 MPa discharge pressure target from typical inlet pressures of 0.05–0.10 MPa. The overall pressure ratio of approximately 30:1 to 60:1 is distributed across three compression rows with two inter-stage cooling points. This multi-stage approach limits the discharge temperature of each stage to below 160°C, preventing thermal degradation of the PTFE sealing elements and extending valve plate life by approximately 50% compared to two-stage designs operating at equivalent overall pressure ratios. The three-row configuration also provides superior force balance characteristics, reducing vibration transmission to the foundation.

2. High-Pressure Oil-Free PTFE Composite Sealing

The LW-9.5/30 employs a proprietary самосмазывающееся поршневое кольцо и узел приводного ремня manufactured from high-density PTFE composites specifically formulated for high-pressure service. These rings are reinforced with glass fiber and bronze particulates to achieve a coefficient of friction below 0.06 without any external hydrocarbon lubrication. At 3.00 MPa discharge pressure, the partial pressure of oil vapor would be approximately 10 times higher than at 0.30 MPa, making oil contamination exponentially more difficult to remove downstream. The LW-9.5/30’s native oil-free design eliminates this challenge entirely, delivering Сертификация ISO 8573-1 Класс 0 without any downstream filtration equipment. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity under the thermal stress of ultra-high-pressure compression.

3. Reinforced Frame Construction for High-Pressure Loads

Основной каркас отлит из Серый чугун GG25 (equivalent to ASTM A48 Class 30B) with substantially reinforced wall sections and integral cooling water passages. The high-pressure cylinder features thickened wall castings, additional external ribbing, and stress-relief grooves to withstand the mechanical stresses associated with 3.00 MPa peak pressures. The three-row configuration provides superior inertial force distribution compared to two-row designs, with the additional row contributing to smoother torque delivery and reduced torsional vibration in the crankshaft. This mechanical refinement is particularly valuable for high-pressure compressors where the peak gas forces on the pistons are substantially elevated.

4. Standard 380V Industrial Motor Drive

The LW-9.5/30 is driven by a 110 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage switchgear or step-down transformers. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the unit accessible to a wide range of industrial facilities. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied on a common skid.

Сценарии применения

High-Pressure Nitrogen Injection for Chemical Synthesis

In chemical process plants, the LW-9.5/30 provides high-pressure nitrogen for ammonia synthesis loop purging, urea reactor inerting, and methanol synthesis catalyst preservation. The 3.00 MPa discharge pressure is sufficient to inject nitrogen directly into high-pressure chemical reactors operating at 2.0–2.5 MPa, maintaining positive inert gas blankets during all phases of operation. The oil-free design is absolutely critical in chemical synthesis applications because any hydrocarbon contamination would poison precious metal catalysts, degrade product quality, and potentially create hazardous conditions in exothermic reactions.

Gas Liquefaction & Cryogenic Storage Booster

In nitrogen liquefaction plants and cryogenic storage facilities, the LW-9.5/30 nitrogen booster compresses nitrogen from the liquefier vaporizer or storage tank to the pressure required for distribution, further processing, or transfer to high-pressure storage vessels. The 3.00 MPa discharge pressure is sufficient for feeding nitrogen into cryogenic liquid storage systems, driving nitrogen through high-pressure heat exchangers, and supplying nitrogen to process equipment requiring elevated pressure. The oil-free design prevents contamination of cryogenic equipment and ensures that liquefied nitrogen product meets the stringent purity requirements of food-grade, medical-grade, and electronics-grade applications.

Petrochemical High-Pressure Vessel Inerting & Testing

In petrochemical and refinery operations, the LW-9.5/30 provides high-pressure nitrogen for reactor catalyst preservation, emergency nitrogen injection into high-pressure vessels, hydrostatic testing of process piping, and pipeline pressure testing. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during startup, shutdown, and upset conditions. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free.

Supercritical Fluid Extraction & Processing

In food processing, pharmaceutical manufacturing, and specialty chemical production, supercritical nitrogen is used for extraction of active compounds, particle formation, and precision cleaning of sensitive components. The critical point of nitrogen is 3.39 MPa and -147°C, meaning the LW-9.5/30’s 3.00 MPa discharge pressure brings nitrogen very close to supercritical conditions when combined with moderate cooling. This near-supercritical nitrogen is used for extracting caffeine from coffee, decaffeinating tea, extracting essential oils, and cleaning precision optical components. The oil-free design is non-negotiable in these applications because any hydrocarbon contamination would be extracted along with the target compounds, compromising product purity and safety.

Материалы и строительство

The LW-9.5/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, thermal resistance, and extended operational life:

Все несущие нагрузку компоненты спроектированы и изготовлены в строгом соответствии с ASME BPVC, раздел VIII, раздел 1 или по китайским стандартам GB 150. Каждый сварной шов проходит радиографический контроль (РТ) по стандарту 100% в соответствии с разделом V, статьей 2 ASME, а каждый готовый сосуд под давлением подвергается гидростатическому испытанию под давлением, в 1,5 раза превышающим максимально допустимое рабочее давление (МДД), с минимальной выдержкой в ​​течение 30 минут. Трубопроводы высокого давления изготавливаются из бесшовной нержавеющей стали SS316 с фланцевыми соединениями класса ANSI 900 для обеспечения герметичности при рабочем давлении 3,00 МПа.

Руководство по установке и техническому обслуживанию

Требования к фундаменту и конструкциям

The LW-9.5/30 has a dry weight of 3.70 tonnes and a center of gravity approximately 850 mm above the baseplate. Due to the three-row configuration, the unbalanced forces are well-distributed, permitting installation on a reinforced concrete inertia block of 6–8 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 7–10 Hz). 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 1.8 m overhead for crane access. Special attention must be paid to the high-pressure discharge piping, which must be properly supported, anchored, and stress-relieved to prevent vibration-induced fatigue at 3.00 MPa.

Проектирование системы охлаждающей воды

Потребность в охлаждающей воде составляет приблизительно 22 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and two intercoolers in parallel. Given the extreme pressure ratio, the intercoolers are absolutely critical for thermal management and must receive priority cooling water flow at all times. 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. A closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended for sites with marginal water quality.

График профилактического технического обслуживания

The oil-free design of the LW-9.5/30 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. The primary consumable wear items are the Поршневые кольца и направляющие кольца из ПТФЭ, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. The high-pressure valve plates on the third stage may require more frequent inspection due to the extreme mechanical stress at 3.00 MPa, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

Сертификаты соответствия и безопасности

The LW-9.5/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Анализ производительности и эффективности

The LW-9.5/30 achieves a specific power consumption of approximately 11.58 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is competitive and often superior to diaphragm compressors, which are the primary alternative for oil-free ultra-high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar applications typically consume 12.0–14.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the LW-9.5/30’s efficiency advantage versus less efficient alternatives yields approximately 38,000–95,000 kWh of annual energy savings. At $0.08/kWh, this represents $3,040–$7,600 in direct electricity cost reduction per year. However, the primary economic justification for the LW-9.5/30 is typically the elimination of oil-related consumables and the avoidance of downstream oil-removal equipment that would be mandatory with lubricated alternatives. At 3.00 MPa, the partial pressure of oil vapor is approximately 10 times higher than at 0.30 MPa, making downstream oil removal exponentially more difficult and expensive. The общая стоимость владения системой сжатия азота сверхвысокого давления is reduced by an estimated 30–45% over a 10-year operational life when oil-free operation is compared to lubricated systems with full downstream purification.

The multi-stage design also contributes to efficiency by reducing the mean effective temperature and improving volumetric efficiency. The two inter-stage cooling points remove approximately 35% of the heat of compression, reducing the work required in subsequent stages and improving the overall isothermal efficiency of the compression process.

Возможности индивидуальной настройки и OEM-производства

We offer comprehensive customization options to adapt the LW-9.5/30 to specific site conditions, integration requirements, and end-user specifications:

• Комплексные решения «под ключ» на салазках: Pre-assembled compressor, motor, dual intercoolers, aftercooler, high-pressure discharge piping, instrumentation, and control panel on a structural steel skid. All high-pressure joints are factory-tested to 1.5× MAWP before shipment. Reduces field installation to electrical and cooling water connections only.
• Конфигурации взрывоопасных зон: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection, automatic ventilation interlocks, and emergency isolation valves incorporated into the control system.
• Расширенное управление технологическими процессами: 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 DCS/SCADA integration. High-pressure safety interlocks including automatic unload on overpressure, emergency isolation valves, and staged pressure relief.
• Охрана окружающей среды: C5-M marine-grade coatings for coastal installations; tropicalized electrical components for 55°C ambient; IP54-rated acoustic enclosures reducing noise from 85 dB(A) to 72 dB(A) at 1 meter.
• OEM и под собственной торговой маркой: Custom paint colors, branded nameplates, and localized documentation for gas equipment distributors and system integrators.

Пользовательские настройки доступны по адресу: Минимальный объем заказа: 1 единица.. Engineering proposals are typically delivered within 5–7 business days. Standard delivery time is 12–14 weeks; expedited delivery within 10 weeks is available for qualifying orders.

Case Study: Chemical Plant High-Pressure Nitrogen System Upgrade

Клиент: A fertilizer manufacturer in Indonesia operating ammonia and urea synthesis plants

Испытание: The plant’s existing high-pressure nitrogen supply consisted of an oil-lubricated compressor (20 years in service) feeding the ammonia synthesis loop and urea reactor inerting systems. Oil contamination in the nitrogen stream had reached 2.8 mg/m³, causing progressive poisoning of the iron-based ammonia synthesis catalyst. Catalyst activity had declined by 15% over 18 months, reducing plant output and increasing energy consumption. The catalyst replacement cost was estimated at $450,000, and the plant faced a potential production shutdown.

Решение: Мы предоставили LW-9.5/30 oil-free nitrogen compressor as the primary high-pressure booster, configured on a custom skid with integrated dual intercoolers, aftercooler, and a Siemens S7-1200 PLC control panel with SCADA integration. The 3.00 MPa discharge pressure met all high-pressure inerting requirements, while the oil-free design eliminated catalyst poisoning. A 2 m³ surge vessel was installed upstream to buffer demand fluctuations from the batch-operated urea reactor inerting system.

Результаты, подтвержденные количественными измерениями, спустя 24 месяца:

• Содержание азота в масле: Reduced from 2.8 mg/m³ to <0.01 mg/m³, achieving ISO 8573-1 Class 0
• Ammonia synthesis catalyst activity: Stabilized, with no further decline observed
• Avoided catalyst replacement cost: $450,000 (deferred indefinitely)
• Plant output improvement: Restored to design capacity, increasing revenue by $2.1M/year
• Энергопотребление: Improved by 5.2% versus the replaced unit, saving $12,800/year
• Внеплановый простой: Zero events in 24 months of continuous operation

“The LW-9.5/30 saved our ammonia plant from a catastrophic catalyst replacement and shutdown. The oil-free design has restored our catalyst activity and eliminated the contamination that was destroying our production. This compressor paid for itself in the first six months through avoided catalyst costs alone.” — Chief Engineer, Fertilizer Manufacturing Plant

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