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LW-40/18 Azot Kompresörü – Zorlu Endüstriyel Uygulamalar için Yüksek Basınçlı Yağsız N2 Takviye Cihazı
Engineered to deliver 40 m³/min at 1.80 MPa discharge pressure, the LW-40/18 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, gas liquefaction pre-compression, and critical petrochemical process applications. Zero oil contamination, continuous-duty rated, and optimized for sustained operation at elevated pressure.
Ürün Genel Bakışı
O LW-40/18 nitrogen compressor occupies a unique position at the intersection of substantial flow capacity and elevated discharge pressure within our oil-free piston compressor portfolio. With a rated capacity of 40 m³/min ve olağanüstü 1,80 MPa deşarj basıncı, this unit addresses the most demanding nitrogen compression requirements in industrial gas infrastructure where both high flow and high pressure are simultaneously required.
What distinguishes the LW-40/18 from conventional high-pressure alternatives is its tamamen yağsız sıkıştırma mekanizması. The piston rings and rider bands are fabricated from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants. This intrinsic oil-free characteristic ensures the nitrogen product stream achieves ISO 8573-1 Sınıf 0 sertifikası natively, making the unit immediately suitable for food-grade nitrogen, pharmaceutical process gas, electronics-grade inerting, and petrochemical reactor blanketing without additional downstream purification equipment.
Kompresör mimarisi şu şekildedir: iki aşamalı, iki sıralı (二列二级) configuration that optimally manages the substantial pressure ratio required for 1.80 MPa discharge. By dividing the compression duty across two cylinders with an inter-stage cooler, the LW-40/18 maintains thermal stability and preserves the integrity of the PTFE sealing elements even under sustained maximum-load operation. The robust construction—2860 × 1685 × 2610 mm Ve 7.00 tonnes—reflects the heavy-duty engineering required for high-pressure industrial service.
Technical Specifications – LW-40/18
| Parametre | Değer | Birim |
|---|---|---|
| Model | LW-40/18 | – |
| Model | İki aşamalı, İki sıralı (二列二级) | – |
| Kapasite | 40 | m³/dak |
| Deşarj Basıncı | 1.80 | MPa |
| Kompresör Boyutları (U × G × Y) | 2860 × 1685 × 2610 | mm |
| Ağırlık | 7.00 | T |
| Güç | 400 | kW |
| Gerilim | 6 bin veya 10 bin | V |
| Gaz Ortamı | Azot (N₂) | – |
| Yağlama | Yağsız | – |
* Tüm özellikler standart referans koşullarında (ISO 1217, Ek C) değerlendirilmiştir. Gerçek performans, saha rakımına, ortam sıcaklığına ve giriş koşullarına bağlı olarak değişebilir.
Başlıca Özellikler ve Mühendislik Avantajları
1. Yüksek Basınçlı Yağsız PTFE Sızdırmazlık Teknolojisi
The LW-40/18 employs a specialized kendinden yağlamalı piston halkası ve sürücü bandı sistemi manufactured from high-performance PTFE composites reinforced with glass fiber, bronze particulates, and molybdenum disulfide. This advanced material formulation achieves a coefficient of friction below 0.05 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover risk. The rings are specifically engineered for the elevated discharge temperatures and pressures associated with 1.80 MPa operation, maintaining dimensional stability and sealing integrity up to 200°C. For operators in regulated industries, this delivers yerel ISO 8573-1 Sınıf 0 uyumluluğu without downstream filtration capital or operating costs.
2. Aşırı Basınç Oranları İçin İki Aşamalı Sıkıştırma
O iki aşamalı sıkıştırma mimarisi of the LW-40/18 is thermodynamically essential for managing the extreme pressure ratio required to achieve 1.80 MPa discharge from near-atmospheric suction. By dividing the compression duty between a low-pressure cylinder and a high-pressure cylinder, the compressor limits the discharge temperature of each stage to below 165°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 45% compared to single-stage designs attempting equivalent pressure ratios. This staged approach is fundamental to achieving reliable continuous operation at 1.80 MPa.
3. Reinforced Heavy-Duty Frame for High-Pressure Service
Ana gövde döküm yöntemiyle üretilmiştir. GG30 gri dökme demir (equivalent to ASTM A48 Class 35B) with thicker wall sections and reinforced ribbing compared to lower-pressure models. The integral cooling water passages are precision-machined to ensure uniform thermal distribution across the cylinder block. The iki sıralı karşılıklı silindir düzenlemesi provides natural first-order force cancellation, reducing unbalanced inertia forces transmitted to the foundation by over 80% versus single-row designs. Despite the 7.00-tonne weight, this mechanical balance permits installation on a reinforced concrete inertia block of 12–14 tonnes, significantly lighter than would be required for an equivalent single-row high-pressure compressor.
4. Yüksek Güçlü Orta Gerilim Motor Tahrik Sistemi
The LW-40/18 is driven by a 400 kW medium-voltage induction motor available in either 6kV or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. The 400 kW power rating reflects the substantial energy input required for high-pressure compression at 40 m³/min capacity. Direct integration into industrial medium-voltage distribution networks eliminates the need for oversized low-voltage switchgear and heavy-gauge cabling. For facilities with existing 6kV or 10kV bus systems, the LW-40/18 offers seamless electrical compatibility, reducing infrastructure costs and improving overall energy efficiency through lower I²R losses.
Uygulama Senaryoları
Petrol Üretimini Geliştirmek için Yüksek Basınçlı Azot Enjeksiyonu
In oilfield operations, the LW-40/18 serves as the primary high-pressure nitrogen injection compressor for enhanced oil recovery (EOR) and pressure maintenance programs. The 1.80 MPa discharge pressure is sufficient for direct injection into reservoir formations at depths up to 1,500 meters, where nitrogen displaces crude oil and maintains reservoir pressure. The 40 m³/min capacity supports multiple injection wells operating simultaneously. The oil-free design is critical in EOR applications because any hydrocarbon contamination from lubricated compressors would alter reservoir wettability and reduce oil displacement efficiency, directly impacting production yields.
Gas Liquefaction Pre-Compression
In small to medium-scale LNG and industrial gas liquefaction plants, the LW-40/18 nitrogen compressor provides the high-pressure nitrogen required for pre-cooling and liquefaction cycle support. The 1.80 MPa discharge pressure is adequate for nitrogen expander cycles and mixed-refrigerant pre-cooling systems. The oil-free compression path ensures that nitrogen used for process inerting and equipment purging does not introduce contaminants that could freeze out in cryogenic heat exchangers, causing blockages and operational disruptions.
Petrochemical Reactor Inerting & Catalyst Preservation
In petrochemical and refinery operations, the LW-40/8 provides high-pressure nitrogen for reactor inerting during startup and shutdown, catalyst bed preservation during extended outages, and emergency nitrogen injection into process vessels. The 1.80 MPa discharge pressure exceeds the operating pressure of most process reactors and vessels, allowing direct nitrogen injection without intermediate boosting. The continuous-duty rating ensures nitrogen availability during extended turnaround campaigns lasting several weeks. The oil-free certification is mandatory for applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free.
Yüksek Basınçlı Boru Hattı Testi ve Devreye Alma
Natural gas and process pipeline construction projects require high-pressure nitrogen for hydrostatic testing, leak testing, drying, and commissioning before introducing hydrocarbon products. The LW-40/18’s 1.80 MPa discharge pressure is suitable for pressure testing pipelines rated up to Class 600 (ANSI B16.5). The 40 m³/min capacity enables rapid pressurization of long pipeline sections, reducing commissioning time and labor costs. The oil-free design prevents oil contamination of pipeline interiors that would require costly cleaning before product introduction.
Malzeme ve İnşaat
The LW-40/18 is constructed from premium materials specifically selected for high-pressure nitrogen service, corrosion resistance, and extended operational life under demanding conditions:
| Bileşen | Malzeme | Özellikler |
|---|---|---|
| Silindir Bloğu | Gri Dökme Demir | GG30 / HT300, reinforced wall sections, integral cooling jackets |
| Krank mili | Dövme Alaşımlı Çelik | 42CrMo4, Q&T, ISO 1940 G2.5 dynamically balanced, nitrided journals |
| Piston Segmanları | PTFE-Cam-Bronz-MoS₂ Kompoziti | Kendinden yağlamalı, 200°C'ye kadar yüksek sıcaklık dayanımına sahip, aşınma oranı <0,03 mm/1000h |
| Binici Grupları | PTFE Kompozit | Piston guidance, anti-scuffing, high-load capacity |
| Valf Plakaları | Paslanmaz çelik | SS316, eşmerkezli halka yaylı, yüksek basınç dayanımlı |
| Bağlantı Çubukları | Babbitt Yataklı Dövme Çelik | Precision-machined, pressure-lubricated big end, high-load design |
| Ara soğutucu | Karbon Çelik Gövde / SS316 Borular | ASME VIII Bölüm 1, 1,5 kat hidrotest, 30 dakika bekleme süresi |
| Son soğutucu | Karbon Çelik Gövde / SS316 Borular | High-pressure finned tube design, 32°C cooling water rated |
| Yüksek Basınçlı Borulama | Dikişsiz Karbon Çelik | ASTM A106 Grade B, Schedule 80, 100% X-ray inspected |
Basınç taşıyan tüm bileşenler, aşağıdakilere sıkı sıkıya uygun olarak tasarlanır ve üretilir: ASME BPVC Bölüm VIII Bölüm 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2. 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 piping connections are 100% ultrasonic tested (UT) to detect any internal defects.
Kurulum ve Bakım Kılavuzu
Temel ve Yapısal Gereksinimler
The LW-40/18 has a dry weight of 7.00 tonnes and a center of gravity approximately 950 mm above the baseplate. The two-row opposed-cylinder design minimizes unbalanced forces, permitting installation on a reinforced concrete inertia block of 12–14 tonnes. The block must be mounted on heavy-duty elastomeric vibration isolators (natural frequency 5–7 Hz) to prevent vibration transmission to adjacent structures and sensitive instrumentation. 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 2.5 m overhead for crane access during major overhauls. The foundation must be designed to withstand the dynamic loads associated with 400 kW motor starting torque.
Soğutma Suyu Sistemi Tasarımı
Soğutma suyu ihtiyacı yaklaşık olarak 48 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches with individual flow control valves. Water quality specifications are stringent due to the high-pressure service: pH 6.5–8.5, total dissolved solids < 400 mg/L, chloride content < 40 mg/L (to prevent SS316 tube corrosion), suspended solids < 20 mg/L, and total hardness < 250 mg/L as CaCO₃. For sites with marginal water quality, a closed-loop cooling tower with side-stream filtration, water softening, and chemical treatment is mandatory to prevent scale formation and corrosion in the high-pressure coolers.
Önleyici Bakım Programı
| Aralık | Servis Kalemi | Eylem Gerekli |
|---|---|---|
| Günlük | Operasyonel Denetim | Check vibration levels, abnormal noise, cooling water flow, discharge temperature, pressure relief valve integrity |
| 250 saat | Vana Plakası Muayenesi | Remove and inspect suction/discharge valves for carbon deposits, spring fatigue, cracking, or seat erosion |
| 1.000 saat | Piston Segmanı Aşınma Değerlendirmesi | Halka oluğu boşluğunu ölçün; boşluk 0,20 mm'yi aşarsa halkaları değiştirin. |
| 3.000 saat | Ara Bakım | Replace all piston rings, rider bands, and valve plate assemblies; inspect intercooler tubes |
| 6.000 saat | Büyük Tadilat | Inspect crankshaft journals, measure main and big-end bearing clearances, replace bearings if >0.06 mm |
The oil-free design of the LW-40/18 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 PTFE piston halkaları ve sürücü bantları, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. Valve plate assemblies generally require refurbishment at 2,000–3,500 hours due to the elevated operating pressures.
Uyumluluk ve Güvenlik Sertifikaları
The LW-40/18 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Bölüm VIII Div.1, GB 150-2011, PED 2014/68/AB Modül A
IEC 60034-1 (IE3 verimliliği), IEC 60204-1, ISO 12100 makine güvenliği
ISO 8573-1 Sınıf 0 (Yağ İçeriği), TÜV Rheinland tarafından bağımsız olarak test edilmiştir.
ISO 9001:2015 (Kalite Yönetimi), ISO 14001:2015 (Çevre Yönetimi)
Nitrogen is classified as a simple asphyxiant gas. At 1.80 MPa, nitrogen releases from the LW-40/18 pose additional hazards due to high-velocity gas jets and rapid expansion cooling. All installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas. Ventilation systems must maintain ambient oxygen above 19.5% volume per OSHA 29 CFR 1910.146. Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic compressor isolation at 18.0% O₂ (hard shutdown). High-pressure relief systems must discharge to safe locations away from personnel areas. All high-pressure piping must be protected against mechanical damage and clearly marked with pressure ratings.
Performans ve Verimlilik Analizi
The LW-40/18 achieves a specific power consumption of approximately 10.00 kW per m³/min of nitrogen delivered at 1.80 MPa discharge pressure. This efficiency metric reflects the substantial thermodynamic work required for high-pressure compression and is competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated screw compressors operating at equivalent pressure ratios typically consume 10.5–12.0 kW/m³/min, while multi-stage diaphragm compressors (often selected for high-pressure oil-free applications) can exceed 14 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the LW-40/18’s efficiency advantage generates approximately 160,000–400,000 kWh of annual energy savings compared to less efficient alternatives. At an average industrial electricity tariff of $0.08/kWh, this represents $12,800–$32,000 in direct operating cost reduction per year. However, the primary economic justification for the LW-40/18 is typically the Petrol ile ilgili sarf malzemelerinin ortadan kaldırılması ve sonraki aşama arıtma ekipmanlarından kaçınılması that would be mandatory with lubricated alternatives.
O yüksek basınçlı nitrojen sıkıştırma için toplam sahip olma maliyeti is further reduced by the absence of oil in the compression path. A typical oil-lubricated compressor of this pressure rating would require high-pressure coalescing filters, activated carbon adsorbers, continuous oil monitoring, and periodic oil replacement that collectively add $15,000–$25,000 annually in operating costs. The LW-40/18’s oil-free design eliminates these expenses entirely while delivering superior product purity.
Özelleştirme ve OEM Yetenekleri
We offer comprehensive customization options to adapt the LW-40/18 to specific site conditions, integration requirements, and end-user specifications:
- Kızaklı Montajlı Anahtar Teslim Paketler: The compressor, motor, intercooler, aftercooler, high-pressure instrumentation, and control panel are pre-assembled on a reinforced structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces field commissioning time by approximately 60%.
- Tehlikeli Alan Yapılandırmaları: ATEX Zone 2 and IECEx compliant motor and electrical enclosures are available for oilfield and petrochemical installations. Integrated gas detection, automatic ventilation interlocks, and explosion-proof instrumentation can be incorporated into the control system.
- Gelişmiş Proses Kontrolü: 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. Automatic load/unload control, anti-surge protection, and emergency shutdown logic are standard.
- Yüksek Basınçlı Paket Seçenekleri: Integrated high-pressure storage vessels, pressure regulation skids, and distribution manifolds can be supplied as part of a complete nitrogen injection package. All high-pressure components are designed and tested to the same standards as the compressor.
- OEM ve Özel Etiket: Custom paint colors, branded nameplates, and localized documentation packages are available for gas equipment distributors and system integrators serving oilfield and industrial markets.
Özel yapılandırmalar şu adresten temin edilebilir: Minimum sipariş miktarı 1 adet. Engineering review and proposal generation typically require 7–10 business days due to the complexity of high-pressure applications. Standard delivery time is 14–16 weeks; repeat orders are delivered in 10–12 weeks from order confirmation.
Case Study: Oilfield Nitrogen Injection for Enhanced Recovery
Müşteri: An independent oil producer operating mature oilfields in the Middle East
Meydan okumak: The client’s oilfields had entered decline phase with reservoir pressure dropping below the bubble point, causing gas breakout and reduced oil mobility. Conventional waterflooding was ineffective due to reservoir heterogeneity. The client required high-pressure nitrogen injection to maintain reservoir pressure and improve sweep efficiency, but existing oil-lubricated compressors were contaminating the injection gas with hydrocarbons, altering reservoir wettability and reducing displacement efficiency.
Çözüm: Biz tedarik ettik LW-40/18 oil-free nitrogen compressor configured on a custom skid with integrated high-pressure aftercooler, moisture separator, and a Siemens S7-1200 PLC control panel with remote monitoring. The 1.80 MPa discharge pressure enabled direct injection into reservoir formations at 1,200–1,400 meters depth. A 10 m³ high-pressure surge vessel was installed downstream to buffer injection rate fluctuations. The skid was designed for desert operation with sand filtration, high-ambient-temperature cooling, and C5-M corrosion protection.
36 Ay Sonra Elde Edilen Nicel Sonuçlar:
- Reservoir pressure: Maintained at 85% of original versus 62% with waterflooding alone
- Oil production rate: 18% kadar artırıldı compared to pre-nitrogen injection baseline
- Azotlu yağ içeriği: <0,01 mg/m³, eliminating reservoir wettability alteration
- Kompresör bulunabilirliği: 97.5% over 36 months, with only scheduled maintenance shutdowns
- Operating cost: 32% lower than the previous oil-lubricated compressor system due to elimination of oil-related maintenance
“The LW-40/18 has been the cornerstone of our nitrogen EOR program. The oil-free design gives us confidence that we’re not compromising reservoir performance, and the reliability has exceeded our expectations in a harsh desert environment.” — Reservoir Engineering Manager
Sıkça Sorulan Sorular ve Seçim Kılavuzu
İlgili Ürünler ve Çözümler
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Ready to Deploy High-Pressure Nitrogen Compression?
Our application engineers are standing by to evaluate your high-pressure nitrogen requirements, suction conditions, discharge pressure targets, and integration constraints. We provide complimentary technical proposals, foundation layout drawings, piping and instrumentation diagrams (P&IDs), and detailed total cost of ownership (TCO) analyses within 48 hours of receiving your inquiry.
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