Азотный компрессор LW-20/18 – безмасляный бустер высокого давления для подачи азота под давлением 1,80 МПа в промышленных условиях.

Компрессор LW-20/18, разработанный для обеспечения производительности 20 м³/мин при давлении на выходе 1,80 МПа, представляет собой двухступенчатый двухрядный безмасляный поршневой азотный компрессор, специально созданный для впрыска азота под высоким давлением, заправки газовых баллонов и сложных технологических процессов в нефтехимической промышленности. Он отличается нулевым загрязнением смазочными материалами, рассчитан на непрерывную работу и оптимизирован для длительной эксплуатации под высоким давлением в промышленных условиях.

Обзор продукта

Он LW-20/18 nitrogen compressor occupies a specialized position within our oil-free piston compressor portfolio, engineered for applications where elevated discharge pressure is the defining operational requirement. With a rated capacity of 20 м³/мин и исключительный Давление на выходе 1,80 МПа, this unit bridges the gap between medium-pressure nitrogen distribution and high-pressure process gas applications that demand substantial flow at elevated pressure.

What fundamentally distinguishes the LW-20/18 from conventional alternatives is its полностью безмасляный компрессионный механизм. The piston rings and rider bands are fabricated from self-lubricating PTFE composite materials that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains entirely free of oil contamination. This intrinsic oil-free characteristic is indispensable for applications requiring Сертификация ISO 8573-1 Класс 0, including high-pressure food packaging nitrogen, pharmaceutical gas cylinder filling, and electronics-grade process gas supply where even trace oil contamination would compromise product integrity.

Архитектура компрессора имеет следующую структуру: двухступенчатый, двухрядный (二列二级) configuration that is thermodynamically optimized for the high pressure ratio demanded by 1.80 MPa discharge. By distributing the pressure ratio across two compression cylinders, the LW-20/18 manages the substantial thermal loads associated with high-pressure compression while preserving the integrity of the PTFE sealing elements. Each stage incorporates an independent high-efficiency intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-load 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-20/18

* All specifications are rated at standard reference conditions (ISO 1217, Annex C). Actual performance may vary based on site altitude, ambient temperature, and inlet conditions. Power rating 240(250) kW indicates standard 240 kW with optional 250 kW motor available.

Основные характеристики и инженерные преимущества

1. Технология герметизации с использованием ПТФЭ под высоким давлением без масла.

The LW-20/18 employs a proprietary самосмазывающееся поршневое кольцо и узел приводного ремня manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates, specifically formulated for high-pressure service. This material achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover into the nitrogen product stream. The high-pressure formulation maintains dimensional stability and sealing integrity at the elevated temperatures associated with 1.80 MPa discharge, ensuring соответствие стандарту ISO 8573-1 класса 0 without downstream oil-filtration equipment. For high-pressure gas cylinder filling and process gas applications, this intrinsic purity is non-negotiable.

2. Двухступенчатое сжатие для экстремальных степеней сжатия.

Он двухступенчатая архитектура сжатия of the LW-20/18 is thermodynamically essential for managing the extreme pressure ratio required to achieve 1.80 MPa discharge from near-atmospheric inlet. By dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder, the compressor limits the mean effective temperature per stage to manageable levels. A dedicated high-performance shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 160°C even at maximum continuous load. This thermal management is critical for preserving PTFE ring integrity under high-pressure conditions and extends valve plate service life by approximately 45% compared to single-stage designs attempting equivalent pressure ratios.

3. Reinforced Frame for High-Pressure Operation

Основной каркас отлит из Серый чугун GG30 (upgraded from GG25 for high-pressure models) with thicker wall sections and integral cooling water passages. The двухрядная противоположно расположенная цилиндрическая компоновка provides natural first-order force cancellation, which is particularly important at the higher gas forces generated by 1.80 MPa discharge pressure. This mechanical balance reduces the unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs, permitting installation on a reinforced concrete inertia block of 8–10 tonnes despite the high-pressure operational loads. The compact dimensions—2500 × 1600 × 2700 mm—are remarkable for a high-pressure compressor of this capacity, enabling installation in existing machinery rooms without extensive civil modifications.

4. Гибкая конфигурация напряжения для промышленной интеграции

The LW-20/18 is driven by a 240(250) kW induction motor available in 380V, 6kV, or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The standard 380V option suits facilities with existing low-voltage distribution infrastructure, while the 6kV and 10kV configurations enable direct integration into medium-voltage industrial bus systems without step-down transformers. This electrical flexibility is particularly valuable for large petrochemical complexes and steel mills where 6kV or 10kV distribution is standard, reducing electrical infrastructure costs and improving overall energy efficiency by minimizing I²R losses in power cabling.

Сценарии применения

Станции заправки баллонов азотом высокого давления

The LW-20/18 is ideally suited for industrial gas cylinder filling operations where nitrogen must be compressed to 1.80 MPa (or higher with cascade filling) for charging standard industrial gas cylinders. Its 20 m³/min capacity supports a high-throughput filling station capable of charging 50–80 cylinders per hour, depending on cylinder size and initial pressure. The oil-free design is critical in cylinder filling because any oil contamination would remain in the cylinder and be delivered to the end-user, potentially contaminating sensitive processes in food, pharmaceutical, and electronics applications. The LW-20/18 high-pressure nitrogen compressor ensures every cylinder meets ISO 8573-1 Class 0 purity standards without additional purification steps.

Азот, получаемый в нефтехимических процессах под высоким давлением

In petrochemical and refinery operations, the LW-20/18 provides high-pressure nitrogen for reactor pressure testing, catalyst regeneration, emergency nitrogen injection into high-pressure vessels, and pipeline pressure testing. The 1.80 MPa discharge pressure is sufficient to pressure-test vessels and pipelines rated to 1.5 MPa working pressure (per ASME B31.3 hydrotest requirements at 1.5× design pressure). The oil-free certification is mandatory for applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free. The continuous-duty rating ensures reliable nitrogen availability during extended turnaround campaigns.

High-Pressure VPSA Nitrogen Boosting

For VPSA nitrogen generators producing high-purity nitrogen at near-atmospheric pressure, the LW-20/18 compresses the low-pressure product to 1.80 MPa for high-pressure distribution. This elevated pressure is particularly valuable for VPSA installations serving multiple high-pressure consumers through a centralized header, where the substantial pressure losses across the distribution network must be overcome. The oil-free compression path is absolutely essential because hydrocarbon contamination would irreversibly poison the carbon molecular sieve adsorbent, permanently degrading separation efficiency and requiring costly adsorbent replacement.

Food & Beverage High-Pressure Nitrogen Injection

Large-scale beverage bottling facilities and food processing plants require high-pressure nitrogen for container pressurization, nitrogen dosing, and controlled atmosphere storage. The LW-20/18’s 1.80 MPa discharge pressure provides the head necessary for high-speed nitrogen dosing into beverage containers before capping, preventing oxygen ingress and extending product shelf life. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-contact nitrogen, eliminating any risk of oil contamination affecting product taste, appearance, or safety.

Материалы и строительство

The LW-20/18 is constructed from premium materials selected for 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 стандарта 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.

Руководство по установке и техническому обслуживанию

Требования к фундаменту и конструкциям

The LW-20/18 has a dry weight of 4.20 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the high-pressure operational loads, the two-row opposed-cylinder design provides excellent force balance, permitting installation on a железобетонный инерционный блок массой 8–10 тонн. The block should be mounted on elastomeric vibration isolators (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.

Проектирование системы охлаждающей воды

Потребность в охлаждающей воде составляет приблизительно 28 м³/ч 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), 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 coolers.

График профилактического технического обслуживания

The oil-free design of the LW-20/18 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 Поршневые кольца и направляющие кольца из ПТФЭ, which typically achieve 3,500–5,500 hours of service life under clean nitrogen conditions at high pressure. This maintenance simplification translates to lower labor costs, reduced spare parts inventory, and higher equipment availability.

Сертификаты соответствия и безопасности

The LW-20/18 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Анализ производительности и эффективности

The LW-20/18 achieves a specific power consumption of approximately 12.0–12.5 kW per m³/min of nitrogen delivered at 1.80 MPa discharge pressure. This efficiency metric is expected for an oil-free piston compressor operating at an extreme pressure ratio (approximately 18:1 from atmospheric inlet), and it compares favorably to diaphragm compressors that are often selected for high-pressure oil-free applications but can consume 15–20 kW/m³/min. For comparison, oil-lubricated reciprocating compressors in similar high-pressure service typically consume 11–13 kW/m³/min but introduce unacceptable oil contamination risk.

Over a standard 8,000-hour annual operating schedule, the LW-20/18’s efficiency advantage versus diaphragm alternatives generates approximately 48,000–120,000 kWh of annual energy savings. At an average industrial electricity tariff of $0.08/kWh, this represents $3,840–$9,600 in direct operating cost reduction per year. However, the primary economic driver for LW-20/18 selection is typically the исключение расходных материалов, связанных с нефтепереработкой, и отказ от использования оборудования для последующей очистки. а не незначительной экономией энергии.

Он общая стоимость владения компрессором высокого давления для подачи азота is further reduced by the absence of oil in the compression path. A typical oil-lubricated high-pressure compressor requires coalescing filters, activated carbon adsorbers, and continuous oil monitoring instrumentation that collectively consume 3–5% of the compressor’s power output and require significant capital investment. The LW-20/18’s oil-free design removes this parasitic load and capital expense entirely.

Возможности индивидуальной настройки и OEM-производства

We offer comprehensive customization options to adapt the LW-20/18 to specific site conditions, integration requirements, and end-user specifications:

• Комплексные решения «под ключ» на салазках: 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. This approach reduces field installation time by approximately 60% and minimizes commissioning risks through factory pre-testing of all systems.
• Cylinder Filling Packages: Optional integrated cylinder filling manifold with pressure sequencing valves, cylinder pressure monitoring, and automatic filling shutoff. Compatible with standard industrial gas cylinder sizes (40L, 50L, 80L) and high-pressure tube trailers.
• Конфигурации взрывоопасных зон: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for installations in petrochemical facilities where explosive atmospheres may occasionally be present. Integrated gas detection and automatic ventilation interlocks can be 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 integration with plant DCS/SCADA systems. Automatic load/unload control and variable frequency drive (VFD) compatibility optimize part-load efficiency.
• Системы защиты окружающей среды: 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 86 dB(A) to 73 dB(A) at 1 meter.
• Программы OEM и производства продукции под собственной торговой маркой: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators.

Пользовательские настройки доступны по адресу: Минимальный объем заказа: 1 единица.. Проверка проектной документации и подготовка предложения обычно занимают 5–7 рабочих дней. Стандартный срок выполнения заказа составляет 12–14 недель; повторные заказы доставляются в течение 8–10 недель с момента подтверждения заказа.

Case Study: Industrial Gas Cylinder Filling Station Modernization

Клиент: A regional industrial gas supplier operating a cylinder filling facility in Thailand

Испытание: The client’s existing high-pressure nitrogen compressor (oil-lubricated reciprocating, 20 years in service) was experiencing progressive oil carryover into filled cylinders, resulting in customer complaints from electronics manufacturers and pharmaceutical companies. Oil contamination levels in filled cylinders reached 3.5 mg/m³, far exceeding the 0.1 mg/m³ specification. The aging compressor also suffered from frequent valve failures and piston ring blow-by, causing unplanned downtime averaging 12 hours per month and reducing filling capacity by 15%.

Решение: Мы предоставили LW-20/18 oil-free nitrogen compressor with an integrated cylinder filling manifold, configured on a custom skid with a Siemens S7-1200 PLC control panel and automatic pressure sequencing. The 1.80 MPa discharge pressure enabled direct filling of 40L and 50L cylinders to 15 MPa working pressure through a three-stage cascade system. The oil-free design eliminated the need for post-filling purification and guaranteed ISO 8573-1 Class 0 compliance in every cylinder.

Результаты, подтвержденные количественными измерениями, спустя 18 месяцев:

• Cylinder oil content: Снижено с 3,5 мг/м³ до <0,01 мг/м³получив сертификат ISO 8573-1 класса 0.
• Жалобы клиентов: Полностью исключено; zero rejected cylinders from electronics and pharmaceutical clients
• Вместимость заправочной станции: Увеличено на 18% due to elimination of unplanned downtime and improved compressor reliability
• Ежегодные затраты на техническое обслуживание: Снижено на 52% ($42,000 to $20,160) through elimination of oil-related repairs and valve failures
• Внеплановый простой: Ноль событий in 18 months of continuous operation

“The LW-20/18 has completely transformed our cylinder filling operation. Our customers no longer reject cylinders for oil contamination, and our maintenance team has gone from fighting breakdowns to performing scheduled preventive maintenance. The integrated filling manifold has also reduced our labor requirements by 30%.” — Операционный директор, поставщик промышленных газов

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