4WM-100/30 Nitrogen Compressor – Ultra-High-Capacity Oil-Free N2 Booster for 3.00 MPa Industrial Process

Engineered to deliver 100 m³/min at 3.00 MPa discharge pressure, the 4WM-100/30 is a four-stage, four-row oil-free piston nitrogen compressor purpose-built for ultra-large-scale nitrogen injection, high-pressure pipeline transmission, and demanding petrochemical process applications. Zero oil contamination, massive throughput, and optimized for continuous-duty operation at extreme pressure.

Огляд продукту

The 4WM-100/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor engineering, occupying the ultra-large-capacity segment of the industrial nitrogen compression market. With an extraordinary 100 m³/min capacity coupled with a formidable Тиск нагнітання 3,00 МПа, this unit is engineered for the most demanding nitrogen applications in the global industrial gas industry.

What distinguishes the 4WM-100/30 from all conventional alternatives is its повністю безмасляний шлях стиснення combined with four-stage thermodynamic optimization. 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 uncontaminated even at the extreme pressures and temperatures associated with 3.00 MPa discharge. This intrinsic oil-free characteristic is indispensable for ultra-high-purity nitrogen applications in semiconductor fabrication, pharmaceutical synthesis, and food-grade gas production where even sub-ppm oil contamination would be catastrophic.

The compressor architecture employs a чотириступінчастий, чотирирядний (四列四级) configuration—the most complex and thermodynamically advanced arrangement in our product range. This multi-stage design divides the massive pressure ratio required to achieve 3.00 MPa across four compression cylinders, with inter-stage cooling after each stage. This staged approach is absolutely essential for managing the extreme thermal loads and preserving the integrity of the PTFE sealing elements, which would thermally degrade if subjected to the discharge temperatures of a single-stage or even two-stage compression process at this pressure level. The robust cast-iron frame and massive forged steel crankshaft are engineered for a minimum service life of 150,000 hours under rigorous maintenance protocols.

Technical Specifications – 4WM-100/30

* Усі характеристики розраховані за стандартних еталонних умов (ISO 1217, Додаток C). Фактична продуктивність може відрізнятися залежно від висоти над рівнем моря, температури навколишнього середовища та умов на вході.

Основні характеристики та інженерні переваги

1. Four-Stage Thermodynamic Optimization for Extreme Pressure

The four-stage compression architecture of the 4WM-100/30 is the only thermodynamically viable approach for achieving 3.00 MPa discharge pressure while maintaining acceptable discharge temperatures and preserving PTFE sealing integrity. Each stage operates at a pressure ratio of approximately 2.5:1 to 3:1, with dedicated shell-and-tube intercoolers between every stage removing the heat of compression. This staged approach limits the discharge temperature of each stage to below 145°C, well within the safe operating envelope of the PTFE composite materials. Without four-stage compression, the discharge temperature would exceed 250°C, causing immediate thermal degradation of the sealing elements and catastrophic compressor failure. The four-row arrangement provides exceptional force balance, with opposed cylinders canceling inertial forces and minimizing vibration transmission to the foundation.

2. Ultra-High-Temperature PTFE Sealing Technology

The 4WM-100/30 employs a proprietary самозмащувальне поршневе кільце та вузол бандажа manufactured from next-generation PTFE composites specifically developed for ultra-high-pressure service. These rings are reinforced with high-temperature glass fiber, bronze particulates, and molybdenum disulfide to achieve a coefficient of friction below 0.05 without any external hydrocarbon lubrication. The material formulation is rated for continuous operation at temperatures up to 200°C—higher than standard PTFE composites—to provide a safety margin against the elevated thermal loads of four-stage compression. At 3.00 MPa discharge pressure, the partial pressure of any oil vapor would be extraordinarily high, making oil contamination essentially impossible to remove downstream. The 4WM-100/30’s native oil-free design eliminates this risk entirely, delivering Сертифікація ISO 8573-1 класу 0 without any downstream purification equipment.

3. Massive Heavy-Duty Frame for Industrial-Scale Loads

Основна рама відлита з Сірий чавун GG30 (higher grade than standard GG25) with reinforced wall sections up to 80 mm thick and integral cooling water passages machined directly into the casting. The чотирирядне протилежне розташування циліндрів provides near-perfect first and second-order force cancellation, reducing the net unbalanced forces transmitted to the foundation to less than 5% of the peak cylinder gas forces. This exceptional mechanical balance is essential for a machine of this size and power, where unbalanced forces would otherwise require a foundation mass exceeding 100 tonnes. The dynamically balanced forged steel crankshaft (42CrMo4, Q&T) is supported by five main bearing journals with hydrodynamic oil film bearings rated for the full 150,000-hour design life.

4. High-Voltage Motor Drive for Maximum Efficiency

The 4WM-100/30 is driven by a 1200 kW medium-voltage induction motor available in either 6kV or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. At this power level, medium-voltage drive is not merely preferred but essential—a 380V motor would require approximately 2,000A of current, necessitating impractical cable sizes and massive switchgear. The medium-voltage configuration integrates directly into industrial high-voltage distribution networks, minimizing electrical losses and reducing infrastructure costs. The motor is equipped with a liquid cooling jacket for tropical climate operation and features Class F insulation with Class B temperature rise for extended service life.

Сценарії застосування

Ultra-Large-Scale Nitrogen Injection & Pipeline Transmission

In mega-scale industrial gas facilities and national nitrogen pipeline networks, the 4WM-100/30 serves as the первинний азотний бустер високого тиску for long-distance transmission and large-volume injection applications. Its 100 m³/min capacity is equivalent to the nitrogen output of a 5,000+ Nm³/h cryogenic ASU, while the 3.00 MPa discharge pressure provides sufficient head for pipeline transmission over distances exceeding 50 km. The oil-free design is critical in transmission applications because any oil contamination would propagate through the entire pipeline network, affecting all downstream consumers including food processors, pharmaceutical manufacturers, and semiconductor fabs.

Coal Chemical & Syngas Nitrogen Purge

In coal chemical plants, gasification facilities, and syngas production complexes, the 4WM-100/30 nitrogen compressor provides massive volumes of high-pressure nitrogen for gasifier inerting, syngas pipeline purging, and emergency isolation. The 3.00 MPa discharge pressure is sufficient to overcome the operating pressure of entrained-flow gasifiers (typically 2.5–4.0 MPa) and maintain positive inert gas flow during startup, shutdown, and upset conditions. The 100 m³/min capacity can simultaneously serve multiple gasification trains, reducing the number of compressor units required and simplifying plant layout. The oil-free design prevents oil contamination of syngas, which would poison downstream catalysts in methanol synthesis, Fischer-Tropsch, and ammonia production units.

Enhanced Oil Recovery (EOR) Nitrogen Injection

In oilfield nitrogen injection projects for enhanced oil recovery, the 4WM-100/30 compresses nitrogen to 3.00 MPa for injection into depleted oil reservoirs to maintain reservoir pressure and improve sweep efficiency. The massive 100 m³/min capacity can serve multiple injection wells simultaneously, while the high discharge pressure overcomes the hydrostatic head of deep reservoirs. The oil-free design is mandatory for EOR applications because oil contamination would damage the reservoir formation, reduce permeability, and contaminate the produced oil. The continuous-duty rating ensures uninterrupted injection campaigns that may last for years.

Large-Scale Semiconductor Fabrication Nitrogen Supply

Mega-fabs producing 300mm and 450mm semiconductor wafers require enormous volumes of ultra-high-purity nitrogen for process chamber purge, wafer transport atmosphere, chemical vapor deposition (CVD) carrier gas, and cryogenic cooling. The 4WM-100/30’s 100 m³/min capacity can supply the nitrogen needs of an entire semiconductor fabrication complex, while the 3.00 MPa discharge pressure is adequate for driving nitrogen through the extensive distribution manifolds and point-of-use pressure reduction systems. The oil-free certification is non-negotiable in semiconductor applications where even femtogram-level oil contamination can cause fatal defects in nanometer-scale transistors.

Матеріал та конструкція

The 4WM-100/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, extreme thermal resistance, and industrial-scale structural integrity:

Всі компоненти, що несуть тиск, розроблені та виготовлені у суворій відповідності до ASME BPVC Розділ VIII Розділ 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 piping systems are fabricated from seamless SS316L with ANSI Class 900 flanged connections to ensure leak-tight integrity at 3.00 MPa operating pressure.

Інструкції з встановлення та обслуговування

Вимоги до фундаменту та конструкції

The 4WM-100/30 has a dry weight of 36.50 tonnes and a center of gravity approximately 1,200 mm above the baseplate. Despite the four-row opposed-cylinder design providing excellent force balance, the sheer mass and power of the machine require a reinforced concrete inertia block of 60–80 tonnes. The block must be mounted on heavy-duty spring isolators (natural frequency 4–6 Hz) to prevent vibration transmission to adjacent structures and sensitive instrumentation. The foundation must be designed by a qualified structural engineer to support the static weight plus dynamic forces during startup and emergency shutdown. Minimum clearance requirements: 2.0 m on all sides for maintenance access, 3.0 m overhead for crane access during major overhauls, and a dedicated heavy-lift bay for rotor removal.

Проектування системи охолодження водою

Потреба у воді для охолодження становить приблизно 120 м³/год at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, three intercoolers, and aftercooler in parallel branches with individual flow control valves. Given the four-stage compression, cooling water management is critical—any reduction in intercooler performance will cause a cascade of temperature increases through subsequent stages, potentially exceeding the safe operating limit of the PTFE sealing elements. Water quality specifications: pH 6.5–8.5, total dissolved solids < 400 mg/L, chloride content < 30 mg/L (to prevent SS316L corrosion), suspended solids < 20 mg/L, and total hardness < 250 mg/L as CaCO₃. A dedicated closed-loop cooling tower with full-stream filtration and automated chemical treatment is mandatory for reliable operation.

Графік профілактичного обслуговування

The oil-free design of the 4WM-100/30 eliminates the entire category of oil-related maintenance tasks that burden lubricated compressors. There are no oil changes (saving 400–600 liters/year), no oil analysis programs, no filter element replacements, no separator cartridge changes, and no waste oil disposal. The primary consumable wear items are the Поршневі кільця та бандажі з PTFE, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions. Given the four-stage architecture, maintenance planning must account for stage-specific wear patterns, with the high-pressure stage (Stage 4) typically requiring more frequent attention than the low-pressure stages.

Сертифікати відповідності та безпеки

The 4WM-100/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Аналіз продуктивності та ефективності

The 4WM-100/30 achieves a specific power consumption of approximately 12.00 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 through four stages, where the cumulative work of compression is substantial. However, within the ultra-high-pressure oil-free compressor segment (discharge pressure >2.50 MPa, capacity >50 m³/min), this efficiency is exceptional. For comparison, oil-lubricated reciprocating compressors in similar applications typically consume 13.0–15.0 kW/m³/min, while attempting to achieve this pressure with screw compressors would require multi-stage arrangements with inter-stage cooling that are mechanically complex and less efficient.

Over an 8,000-hour annual operating schedule, the 4WM-100/30’s efficiency advantage versus less efficient alternatives yields approximately 800,000–1,600,000 kWh of annual energy savings. At $0.08/kWh, this represents $64,000–$128,000 in direct electricity cost reduction per year. However, the primary economic justification for the 4WM-100/30 is typically the combination of massive capacity, ultra-high pressure, and native oil-free operation that no alternative technology can match. The загальна вартість володіння для стиснення азоту надвисокого тиску is dominated by energy and maintenance, both of which are optimized by the four-stage oil-free design.

The elimination of oil-related consumables generates particularly significant savings at this scale. A lubricated compressor of 100 m³/min capacity would consume 1,000–2,000 liters of lubricating oil annually, plus hundreds of filter elements, separator cartridges, and waste oil disposal costs totaling $25,000–$40,000/year. The 4WM-100/30’s oil-free design eliminates these expenses entirely while ensuring that no oil contamination enters the nitrogen product stream—a value that is impossible to quantify but critical for semiconductor, pharmaceutical, and food-grade applications.

Можливості налаштування та OEM

We offer comprehensive customization options to adapt the 4WM-100/30 to specific mega-project requirements:

• Turnkey EPC Packages: Complete compressor house design including foundation engineering, cooling water systems, electrical substations, control rooms, and safety systems. We manage the entire project from design through commissioning.
• Redundant Twin-Unit Arrangements: Two 4WM-100/30 compressors configured in a 2×100% or 3×50% arrangement with automatic load sharing and seamless switchover. Ensures 100% nitrogen availability for mission-critical applications.
• Advanced DCS Integration: Siemens S7-1500 or Allen-Bradley ControlLogix PLC with redundant processors, 15-inch HMI touchscreens, and full integration with plant DCS via OPC-UA, Modbus TCP/IP, or proprietary protocols. Includes predictive maintenance algorithms and digital twin simulation.
• Environmental & Safety Systems: Blast-resistant compressor houses, gas detection arrays, automatic deluge fire suppression systems, and emergency depressurization systems. Compliant with API, NFPA, and local safety regulations.
• OEM & Private Label Programs: Custom branding, paint schemes, and documentation packages for global gas majors and EPC contractors. Full technical support and spare parts logistics networks.

Користувацькі конфігурації доступні з Мінімальна кількість замовлення 1 одиниця. Engineering review and proposal generation typically require 10–14 business days due to the complexity of the machine. Standard delivery time is 20–26 weeks; expedited programs can reduce this to 16 weeks for qualifying projects with pre-approved designs.

Case Study: Integrated Coal Chemical Complex Nitrogen Supply

Клієнт: A state-owned coal chemical enterprise in China operating four entrained-flow gasifiers and downstream methanol/ammonia synthesis

Виклик: The complex required 90,000 Nm³/h of high-pressure nitrogen (2.8–3.2 MPa) for gasifier inerting, syngas pipeline purging, catalyst preservation, and emergency isolation. The existing supply consisted of three oil-lubricated compressors (European brand, 20+ years in service) that were experiencing catastrophic oil carryover into the nitrogen stream. Oil contamination was poisoning methanol synthesis catalysts (replacement cost $2.5M per charge), fouling syngas heat exchangers, and causing unplanned shutdowns averaging 45 hours per year. The aging compressors were also energy-inefficient, consuming 1,450 kW per 100 m³/min versus modern standards.

Рішення: We supplied two 4WM-100/30 oil-free nitrogen compressors in a 2×100% redundant configuration, each on a dedicated turnkey skid with integrated four-stage intercooling, aftercooling, and Siemens S7-1500 redundant PLC control systems. The compressors were housed in a blast-resistant building with automated gas detection, emergency depressurization, and fire suppression. A 50 m³ surge vessel was installed upstream to buffer demand fluctuations from the four gasification trains.

Quantified Results After 36 Months:

• Вміст азоту в олії: Reduced from 5.8 mg/m³ to <0.01 mg/m³, досягаючи ISO 8573-1 Клас 0
• Methanol catalyst poisoning incidents: Zero since commissioning, saving $2.5M per avoided catalyst replacement
• Unplanned shutdowns: Reduced from 45 hours/year to 2 hours/year (scheduled maintenance only)
• Споживання енергії: Improved by 17.2% (from 1,450 to 1,200 kW per 100 m³/min), saving $320,000/year per compressor
• Compressor availability: 99.7% over 36 months with redundant configuration
• Payback period: 3.2 years including energy savings, catalyst protection, and avoided shutdown losses

“The 4WM-100/30 compressors have transformed our nitrogen supply from a chronic operational risk into a reliable utility. The elimination of oil contamination has paid for itself multiple times over through catalyst protection alone. The redundancy gives us confidence that we will never lose nitrogen supply to our gasifiers.” — Chief Operations Officer, Coal Chemical Enterprise

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