Beskrivning
LW-25/10 kvävgaskompressor – Högtrycks oljefri N2-booster för industriella applikationer på 1,00 MPa
Engineered to deliver 25 m³/min at 1.00 MPa discharge pressure, the LW-25/10 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, pipeline boosting, and demanding petrochemical process applications. Zero lubricant contamination, continuous-duty rated, and optimized for 24/7 industrial operation at elevated pressure.
Produktöversikt
De LW-25/10 nitrogen compressor represents a specialized high-pressure solution within our oil-free piston compressor portfolio, engineered for applications where both substantial flow and elevated discharge pressure are non-negotiable requirements. With a rated capacity of 25 m³/min och en exceptionell 1.00 MPa discharge pressure, this unit occupies a unique position at the intersection of high-flow and high-pressure nitrogen compression.
What distinguishes the LW-25/10 from conventional high-pressure alternatives is its helt oljefri kompressionsmekanism. The piston rings and rider bands are fabricated from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This intrinsic oil-free characteristic delivers ISO 8573-1 Klass 0-certifiering natively, making the unit immediately suitable for the most demanding applications including food-grade nitrogen, pharmaceutical process gas, semiconductor fabrication, and petrochemical reactor inerting without additional downstream purification.
Kompressorn använder en tvåsteg, tvårad (二列二级) configuration that carefully manages the high pressure ratio required for 1.00 MPa discharge. By dividing the compression work across two cylinders with an optimized inter-stage pressure, the LW-25/10 maintains thermal stability and preserves the integrity of the PTFE sealing elements even under sustained maximum-load operation. The robust cast-iron frame and precision-balanced forged steel crankshaft are rated for a minimum service life of 120 000 timmar enligt standardiserade underhållsprotokoll.
Technical Specifications – LW-25/10
| Parameter | Värde | Enhet |
|---|---|---|
| Modell | LW-25/10 | – |
| Mönster | Tvåsteg, tvåradigt (二列二级) | – |
| Kapacitet | 25 | m³/min |
| Utloppstryck | 1.00 | MPa |
| Kompressorstorlek (L × B × H) | 2500 × 1600 × 2700 | mm |
| Vikt | 4.50 | t |
| Driva | 200 | kW |
| Spänning | 380 / 6k eller 10k | V |
| Gasmedium | Kväve (N₂) | – |
| Smörjning | Oljefri | – |
* Alla specifikationer är klassade vid standardreferensförhållanden (ISO 1217, bilaga C). Faktisk prestanda kan variera beroende på platsens höjd över havet, omgivningstemperatur och inloppsförhållanden.
Viktiga funktioner och tekniska fördelar
1. High-Temperature Oil-Free PTFE Sealing Technology
The LW-25/10 utilizes a proprietary självsmörjande kolvring och ryttarbandsenhet manufactured from high-performance 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 rings are engineered for the elevated discharge temperatures associated with 1.00 MPa operation, maintaining dimensional stability and sealing integrity up to 190°C. For operators in regulated industries, this delivers inbyggd ISO 8573-1 klass 0-överensstämmelse without the capital cost, maintenance burden, or energy penalty of downstream oil-filtration systems.
2. Optimized Two-Stage High-Pressure Thermodynamic Design
De tvåstegskompressionsarkitektur of the LW-25/10 is thermodynamically optimized for the demanding 1.00 MPa discharge pressure target. By carefully dividing the pressure ratio between a low-pressure cylinder and a high-pressure cylinder with an optimized inter-stage pressure, the compressor achieves a significantly lower mean effective temperature per stage compared to single-stage designs. A high-efficiency shell-and-tube intercooler between stages removes the heat of compression, maintaining discharge temperatures below 160°C even at maximum continuous load. This advanced thermal management is essential for preserving PTFE ring integrity at high pressure ratios and extends valve plate service life by approximately 45% versus single-stage alternatives.
3. Reinforced Cast-Iron Frame with Force Balance
Huvudramen är gjuten av GG25 grått gjutjärn (equivalent to ASTM A48 Class 30B) with reinforced wall sections and integral cooling water passages. The tvåradig motstående cylindrar provides natural first-order force cancellation, reducing unbalanced inertia forces transmitted to the foundation by over 80% compared to single-row designs. This mechanical advantage is particularly valuable for the LW-25/10 given its high-pressure operation, where reciprocating forces are substantially higher than low-pressure equivalents. The reduced vibration transmission permits installation on a lighter reinforced concrete inertia block (minimum 8 tonnes versus 12+ tonnes for single-row high-pressure equivalents), reducing civil engineering costs.
4. Flexibel spänningskonfiguration för industriell integration
The LW-25/10 is driven by a 200 kW induction motor available in 380V, 6kV, or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The flexible voltage options allow direct integration into diverse industrial electrical infrastructures: the 380V configuration suits facilities with existing low-voltage distribution, while the 6kV and 10kV options eliminate the need for step-down transformers in large industrial plants with medium-voltage bus systems. This electrical versatility reduces infrastructure costs and improves overall energy efficiency by minimizing transformation losses.
Applikationsscenarier
High-Pressure Nitrogen Injection for Petrochemical Reactors
In petrochemical and refining operations, the LW-25/10 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, emergency nitrogen injection, and process vessel purging. The 1.00 MPa discharge pressure is sufficient to overcome the operating pressures of typical fixed-bed reactors, fluid catalytic cracking units, and hydrocracker systems, allowing direct nitrogen injection without intermediate boosting. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround campaigns. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free to prevent catalyst poisoning or product contamination.
Högtrycks-VPSA-kvävgasboosterstationer
För VPSA-kvävegeneratorer som producerar kväve med hög renhet vid nära atmosfärstryck, LW-25/10 high-pressure nitrogen booster compresses the low-pressure product to 1.00 MPa for demanding distribution applications. The elevated discharge pressure is particularly valuable for VPSA installations serving high-pressure process consumers, long-distance pipeline networks with significant friction losses, or facilities requiring nitrogen at pressure for direct injection into process vessels. The oil-free compression path is absolutely essential because hydrocarbon contamination would permanently poison the carbon molecular sieve adsorbent, degrading separation efficiency and requiring costly adsorbent replacement.
Pipeline Nitrogen Boosting & Pressure Maintenance
Industrial gas distribution networks spanning multiple kilometers require nitrogen at elevated pressure to overcome pipeline friction losses and maintain adequate flow at remote consumers. The LW-25/10’s 1.00 MPa discharge pressure provides sufficient head for distribution over distances up to 5 km through DN200 pipelines, making it suitable for centralized nitrogen supply to large industrial complexes, chemical parks, and integrated manufacturing facilities. The 25 m³/min capacity supports multiple high-pressure consumers simultaneously, including reactor inerting systems, tank blanketing stations, and emergency nitrogen injection points.
High-Pressure Food Packaging & Modified Atmosphere Systems
Large-scale food packaging facilities with high-speed MAP (Modified Atmosphere Packaging) lines require nitrogen at elevated pressure to achieve rapid gas displacement in packaging chambers. The LW-25/10’s 1.00 MPa discharge pressure enables fast-fill nitrogen injection, reducing cycle times and increasing packaging line throughput. The oil-free certification ensures compliance with FDA 21 CFR 173.310 and EU Regulation 231/2012 for food-grade nitrogen. The absence of oil contamination eliminates risks of off-flavors, rancidity, or product discoloration that can occur with lubricated compressors in food-contact applications.
Material och konstruktion
The LW-25/10 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal resistance, and extended operational life:
| Komponent | Material | Specifikation |
|---|---|---|
| Cylinderblock | Grått gjutjärn | GG25 / HT250, reinforced walls, integral cooling jackets |
| Vevaxel | Smidd legeringsstål | 42CrMo4, Q&T, ISO 1940 G2.5 dynamiskt balanserad |
| Kolvringar | PTFE-glas-bronskomposit | Självsmörjande, tål höga temperaturer upp till 190°C |
| Ryttarband | PTFE-komposit | Kolvstyrning, slitageskydd, slitage <0,04 mm/1000h |
| Ventilplattor | Rostfritt stål | SS316, high-pressure concentric ring spring-loaded design |
| Vevstakar | Smidd stål med Babbitt-lager | Precisionsbearbetad, oljesmord big end |
| Intercooler | Kolstålsskal / SS316-rör | ASME VIII Div.1, 1,5× vattentest, 30 min hålltid |
| Efterkylare | Kolstålsskal / SS316-rör | High-efficiency finned tube, 32°C cooling water rated |
| Högtrycksrörledningar | Sömlöst kolstål | ASTM A106 Grade B, Schedule 80 |
Alla tryckbärande komponenter är konstruerade och tillverkade i strikt enlighet med ASME BPVC avsnitt VIII division 1 eller kinesiska GB 150-standarder. Varje svetsfog genomgår 100% radiografisk inspektion (RT) enligt ASME avsnitt V, artikel 2, och varje färdigställt tryckkärl utsätts för ett hydrostatiskt tryckprov vid 1,5 gånger det maximalt tillåtna arbetstrycket (MAWP) under en minsta hållperiod på 30 minuter.
Installations- och underhållsriktlinjer
Grund- och strukturkrav
The LW-25/10 has a dry weight of 4.50 tonnes and a center of gravity approximately 950 mm above the baseplate. Due to the two-row opposed-cylinder design, unbalanced forces are significantly reduced despite the high-pressure operation, permitting installation on a reinforced concrete inertia block of 8–10 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz) to prevent vibration transmission. 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.
Design av kylvattensystem
Kylvattenbehovet är ungefär 28 m³/h 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 cooling circuits.
Schema för förebyggande underhåll
| Intervall | Serviceartikel | Åtgärd krävs |
|---|---|---|
| Dagligen | Driftsinspektion | Kontrollera vibrationsnivåer, onormalt ljud, kylvattenflöde, utloppstemperatur och tryck |
| 250 timmar | Inspektion av ventilplatta | Ta bort och inspektera sug-/utloppsventilerna för kolavlagringar, fjäderutmattning eller sprickbildning. |
| 1 000 timmar | Bedömning av kolvringsslitage | Mät ringspårens spel; byt ut ringarna om spelet överstiger 0,20 mm |
| 4 000 timmar | Mellanöversyn | Byt ut alla kolvringar, rytmband och ventilplattenheter |
| 8 000 timmar | Stor översyn | Kontrollera vevaxelns lagertappar, mät huvudlagerspelet, byt lager om >0,08 mm |
The oil-free design of the LW-25/10 dramatically reduces maintenance complexity 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 PTFE-kolvringar och ryttarband, som vanligtvis uppnår 4 000–6 000 timmars livslängd under rena kvävgasförhållanden. Denna förenkling av underhållet leder till lägre arbetskostnader, minskat reservdelslager och högre tillgänglighet av utrustning.
Efterlevnads- och säkerhetscertifieringar
The LW-25/10 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Sektion VIII Div.1, GB 150-2011, PED 2014/68/EU Modul A
IEC 60034-1 (IE3 effektivitet), IEC 60204-1, ISO 12100 maskinsäkerhet
ISO 8573-1 Klass 0 (oljeinnehåll), oberoende testad av TÜV Rheinland
ISO 9001:2015 (Kvalitetsledning), ISO 14001:2015 (Miljöledning)
Nitrogen is classified as a simple asphyxiant gas. All LW-25/10 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas where nitrogen leakage could accumulate. Ventilation systems must be engineered to maintain ambient oxygen concentrations above 19.5% volume per OSHA 29 CFR 1910.146 (Permit-Required Confined Spaces). Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic compressor isolation at 18.0% O₂ (hard shutdown). Personnel entry procedures into enclosed compressor rooms must include portable oxygen monitors and a buddy-system protocol. Additionally, the 1.00 MPa discharge pressure requires all downstream piping and vessels to be rated for the maximum working pressure with appropriate safety relief devices.
Prestanda- och effektivitetsanalys
The LW-25/10 achieves a specific power consumption of approximately 8.00 kW per m³/min of nitrogen delivered at 1.00 MPa discharge pressure. This efficiency metric is respectable for an oil-free piston compressor operating at a high pressure ratio, reflecting the thermodynamic challenges of compressing nitrogen to 1.00 MPa. For comparison, oil-lubricated screw compressors in similar high-pressure applications typically consume 8.5–9.5 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-25/10’s efficiency advantage generates approximately 40,000–100,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $3,200–$8,000 in direct operating cost reduction per year. However, the primary economic driver for LW-25/10 selection is typically the eliminering av oljerelaterade förbrukningsvaror och nedströms reningsutrustning snarare än marginella energibesparingar.
De total ägandekostnad för högtryckskvävgaskompression is significantly reduced by the absence of oil in the compression path. A typical oil-lubricated compressor of this pressure rating requires coalescing filters, activated carbon adsorbers, oil monitoring instrumentation, and periodic oil changes that collectively add $8,000–$15,000 in annual operating costs. The LW-25/10’s oil-free design eliminates these expenses entirely, while also removing the 3–5% energy penalty associated with downstream oil-removal equipment.
Anpassning och OEM-funktioner
We provide comprehensive customization options to adapt the LW-25/10 to specific site conditions, integration requirements, and end-user specifications:
- Nyckelfärdiga paket för medarmontering: Kompressor, motor, intercooler, efterkylare, högtrycksinstrument och kontrollpanel är förmonterade på en stålkonstruktion med integrerade lyftöglor och förankringsbultmallar. Förtestning av alla system i fabriken minskar driftsättningstiden med cirka 60% och minimerar uppstartsriskerna.
- Konfigurationer för farliga områden: Motor- och elkapslingar som uppfyller ATEX-zon 2 och IECEx finns tillgängliga för installationer i petrokemiska anläggningar där explosiv atmosfär ibland kan förekomma. Integrerade gasdetekterings- och automatiska ventilationsspärrar kan integreras i styrsystemet.
- Avancerad processkontroll: 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.
- Alternativ för högtryckspaket: Integrated high-pressure receiver vessels, pressure regulation skids, and nitrogen distribution manifolds can be supplied as part of a complete system package. All high-pressure components are designed and tested to ASME BPVC standards.
- OEM- och Private Label-program: Anpassade färger, namnskyltar med märkesprofil och lokaliserade dokumentationspaket finns tillgängliga för distributörer av gasutrustning och systemintegratörer. Tekniska manualer, reservdelslistor och underhållsprocedurer kan tillhandahållas på flera språk.
Anpassade konfigurationer är tillgängliga från MOQ 1 enhetTeknisk granskning och offertgenerering tar vanligtvis 5–7 arbetsdagar. Standardleveranstiden är 12–14 veckor; återbeställningar levereras inom 8–10 veckor från orderbekräftelse.
Case Study: Petrochemical Reactor Nitrogen Injection System
Klient: A major petrochemical complex in the Middle East operating polyethylene and polypropylene production units
Utmaning: The client’s existing oil-lubricated nitrogen compressor (American brand, 12 years in service) was experiencing progressive oil carryover into the nitrogen injection system used for reactor inerting and catalyst bed preservation. Oil contamination levels reached 3.5 mg/m³, exceeding the 0.1 mg/m³ limit specified by the catalyst supplier. The oil was deactivating the Ziegler-Natta catalyst, reducing polymer yield by 2.8% and requiring premature catalyst replacement at a cost of $180,000 per campaign. Additionally, the compressor’s 0.70 MPa discharge pressure was insufficient for new high-pressure reactor designs requiring 0.95 MPa nitrogen.
Lösning: Vi levererade en LW-25/10 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with integrated intercooler, aftercooler, high-pressure receiver vessel, and a Siemens S7-1200 PLC control panel with DCS integration. The 1.00 MPa discharge pressure met the new reactor requirements with margin, while the oil-free design eliminated catalyst contamination. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from multiple reactor units.
Kvantifierade resultat efter 18 månader:
- Kvävehalt av olja: Minskad från 3,5 mg/m³ till <0,01 mg/m³, uppnår ISO 8573-1 klass 0-certifiering
- Catalyst deactivation incidents: Eliminerad helt, restoring polymer yield to design specifications
- Catalyst replacement frequency: Extended from 12 months to 24 months, saving $180,000 per cycle
- Årlig underhållskostnad: Minskad med 48% through elimination of oil-related repairs and separator overhauls
- Oplanerad driftstopp: Noll händelser in 18 months of continuous operation
“The LW-25/10 solved our catalyst contamination problem permanently. The 1.00 MPa pressure gives us the margin we need for new reactor designs, and the oil-free design has eliminated our most persistent operational headache. The payback was under 14 months.” — Process Engineering Manager, Petrochemical Complex
Vanliga frågor och urvalsguide
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