描述
LW-16.5/13 Nitrogen Compressor – Medium-Flow High-Pressure Oil-Free N2 Booster for Demanding Industrial Applications
Engineered to deliver 16.5 m³/min at 1.30 MPa discharge pressure, the LW-16.5/13 is a two-stage, two-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, chemical synthesis, and specialized industrial gas distribution where elevated pressure and uncompromised purity converge. Zero lubricant contamination, continuous-duty rated, and optimized for 24/7 operation in the most demanding process environments.
产品概述
这 LW-16.5/13 nitrogen compressor occupies a specialized niche within our oil-free piston compressor portfolio, bridging the gap between medium-flow capacity and high-pressure discharge requirements. With a rated capacity of 16.5 m³/min and an elevated discharge pressure of 1.30 MPa, this unit is engineered for process applications where nitrogen must be delivered at pressures substantially higher than conventional distribution headers.
What distinguishes the LW-16.5/13 from standard nitrogen compressors is its ability to achieve 1.30 MPa discharge pressure while maintaining complete oil-free integrity throughout the compression path. The piston rings and rider bands are fabricated from high-performance self-lubricating PTFE composites specifically formulated for elevated pressure and temperature conditions. This ensures the nitrogen stream remains completely free of hydrocarbon contamination, achieving ISO 8573-1 0级认证 without any downstream purification equipment. For chemical synthesis, high-pressure reactor inerting, and specialty gas applications, this native purity is non-negotiable.
The compressor utilizes a two-stage, two-row (二列二级) configuration that is thermodynamically essential for managing the substantial pressure ratio required to reach 1.30 MPa. The pressure ratio is optimally distributed between a low-pressure cylinder and a high-pressure cylinder, with an inter-stage cooler removing the heat of compression between stages. This staged approach limits the discharge temperature of each stage to below 160°C, preserving the dimensional stability of the PTFE sealing elements and extending valve plate service life. The robust cast-iron frame and precision-balanced forged steel crankshaft are rated for a minimum operational life of 120,000 小时 under standard maintenance protocols.
Technical Specifications – LW-16.5/13
| 范围 | 价值 | 单元 |
|---|---|---|
| 模型 | LW-16.5/13 | – |
| 图案 | Two-stage, Two-row (二列二级) | – |
| 容量 | 16.5 | 立方米/分钟 |
| 排气压力 | 1.30 | 兆帕 |
| 压缩机尺寸（长×宽×高） | 2675 × 1550 × 2520 | 毫米 |
| 重量 | 3.00 | t |
| 力量 | 160 | 千瓦 |
| 电压 | 380 | V |
| 气体介质 | 氮气（N₂） | – |
| 润滑 | 无油 | – |
* 所有规格均在标准参考条件下（ISO 1217，附录 C）测得。实际性能可能因现场海拔、环境温度和进气条件而异。
主要特性及工程优势
1. High-Pressure Oil-Free PTFE Sealing Technology
The LW-16.5/13 employs an advanced self-lubricating piston ring and rider band system manufactured from high-density PTFE composites reinforced with glass fiber, carbon fiber, and bronze particulates. This specialized formulation is engineered for the elevated pressures and temperatures associated with 1.30 MPa discharge operation, achieving a coefficient of friction below 0.06 without any hydrocarbon lubrication. The rings maintain dimensional stability up to 190°C, ensuring reliable sealing performance even during sustained high-pressure operation. For chemical process operators, this delivers native ISO 8573-1 Class 0 compliance without downstream oil-filtration capital expenditure or maintenance burden.
2. Two-Stage Compression for Extreme Pressure Ratios
这 two-stage compression architecture is not merely beneficial but essential for achieving 1.30 MPa discharge pressure from near-atmospheric inlet conditions. The pressure ratio is divided between a low-pressure cylinder and a high-pressure cylinder, with a high-efficiency shell-and-tube intercooler removing the heat of compression between stages. This staged approach limits the discharge temperature of each stage to below 160°C, preventing thermal degradation of the PTFE sealing elements and extending valve plate service life by approximately 50% compared to single-stage designs attempting equivalent pressure ratios. The intercooler is oversized for the duty, providing a safety margin during ambient temperature excursions.
3. Compact Yet Robust Frame Construction
主框架由……铸造而成 GG25 gray cast iron (equivalent to ASTM A48 Class 30B) with integral cooling water passages. Despite the high-pressure capability, the LW-16.5/13 maintains a relatively compact footprint of 2675 × 1550 × 2520 mm and a weight of just 3.00 tonnes. The two-row opposed-cylinder arrangement provides inherent first-order force cancellation, reducing vibration transmission and permitting installation on a modest reinforced concrete inertia block of 5–6 tonnes. This compactness is particularly advantageous for retrofit installations in existing chemical plants and process facilities where space and foundation capacity are limited.
4. Standard 380V Industrial Motor Drive
The LW-16.5/13 is driven by a 160 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 infrastructure, step-down transformers, or specialized switchgear. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the LW-16.5/13 an attractive upgrade path for facilities transitioning from bottled high-pressure nitrogen or hydraulic gas boosters to continuous on-site compression.
应用场景
High-Pressure Chemical Synthesis & Reactor Inerting
In chemical manufacturing facilities, the LW-16.5/13 provides high-pressure nitrogen for reactor inerting, catalyst bed preservation, and emergency nitrogen injection into process vessels operating at elevated pressures. The 1.30 MPa discharge pressure is sufficient to overcome the internal pressure of most batch reactors, autoclaves, and high-pressure synthesis loops, allowing direct nitrogen injection without intermediate boosting. The oil-free design is absolutely critical in chemical synthesis because any hydrocarbon contamination would poison precious metal catalysts, initiate unwanted side reactions, or compromise product purity in fine chemical and pharmaceutical manufacturing.
High-Pressure VPSA Nitrogen Boosting
For VPSA nitrogen generators producing high-purity nitrogen at near-atmospheric pressure, the LW-16.5/13 nitrogen booster compresses the low-pressure product to 1.30 MPa for high-pressure distribution to demanding process consumers. The 16.5 m³/min capacity is well-matched to medium-scale VPSA installations serving chemical plants, specialty gas facilities, and high-pressure blanketing applications. The oil-free compression path protects the carbon molecular sieve from hydrocarbon poisoning, preserving adsorbent life and maintaining nitrogen purity.
Oil & Gas Pipeline Purging & Pressure Testing
In oil and gas pipeline construction and maintenance, nitrogen is used for pipeline purging, hydrostatic test displacement, and dried-inert gas packing before commissioning. The LW-16.5/13’s 1.30 MPa discharge pressure is adequate for purging medium-diameter pipelines (up to 24-inch nominal bore) and for hydrotest displacement in pipelines operating at pressures up to 10 MPa. The oil-free design prevents hydrocarbon contamination of pipeline interiors, which is essential for gas transmission pipelines where even trace oil residues could foul gas quality meters, compressor stations, and end-user equipment.
Specialty Gas & Cylinder Filling Operations
Specialty gas facilities and industrial gas distributors require high-pressure nitrogen for cylinder filling, bundle charging, and gas mixture preparation. The LW-16.5/13’s 1.30 MPa discharge pressure is sufficient to fill high-pressure nitrogen cylinders (typically 15 MPa working pressure) through a multi-stage gas booster or compressor cascade. The oil-free certification ensures that filled cylinders meet the purity specifications of analytical grade, ultra-high purity, and research-grade nitrogen without requiring additional purification steps.
材料与施工
The LW-16.5/13 is constructed from premium materials selected for high-pressure nitrogen compatibility, elevated temperature resistance, and extended operational life:
| 成分 | 材料 | 规格 |
|---|---|---|
| Cylinder Block | 灰铸铁 | GG25 / HT250, integral cooling water jackets |
| 曲轴 | 锻造合金钢 | 42CrMo4, Q&T, ISO 1940 G2.5 dynamically balanced |
| 活塞环 | PTFE-Glass-Carbon-Bronze Composite | Self-lubricating, high-temp rated to 190°C |
| 骑手带 | 聚四氟乙烯复合材料 | Piston guidance, anti-scuffing, wear rate <0.04 mm/1000h |
| 阀板 | 不锈钢 | SS316, concentric ring spring-loaded, high-pressure rated |
| Connecting Rods | Forged Steel with Babbitt Bearings | Precision-machined, oil-lubricated big end |
| Intercooler | 碳钢外壳/316不锈钢管材 | ASME VIII Div.1, 1.5× hydrotest, 30 min hold |
| 后冷却器 | 碳钢外壳/316不锈钢管材 | Finned tube design, 32°C cooling water rated |
| 高压管道 | Seamless Carbon Steel | ASTM A106 Grade B, 1.5× design pressure rated |
所有承压部件的设计和制造均严格按照以下规定进行： ASME BPVC 第 VIII 节第 1 部分 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.
安装和维护指南
Foundation & Spatial Requirements
The LW-16.5/13 has a dry weight of 3.00 tonnes and a center of gravity approximately 800 mm above the baseplate. The two-row opposed-cylinder design provides excellent force balance, allowing installation on a reinforced concrete inertia block of 5–6 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 8–12 Hz) to prevent vibration transmission. Required clearances: 1.2 m on the non-drive side for valve access, 1.0 m on the drive side for motor maintenance, and 1.5 m overhead for crane access during major overhauls. The compact footprint makes the LW-16.5/13 suitable for installation in existing machinery rooms with limited floor space.
冷却水系统设计
冷却水需求量约为 18 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and intercooler 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 compact closed-loop cooling tower with side-stream filtration is recommended to prevent scale formation and corrosion in the high-pressure cooling circuits.
预防性维护计划
| 间隔 | 服务项目 | 需要采取的行动 |
|---|---|---|
| 日常的 | 运行检查 | Check vibration levels, abnormal noise, cooling water flow, discharge temperature and pressure |
| 250小时 | Valve Plate Inspection | Remove and inspect suction/discharge valves for carbon deposits, spring fatigue, or cracking |
| 1000小时 | Piston Ring Wear Assessment | 测量活塞环槽间隙；如果间隙超过 0.20 毫米，则更换活塞环。 |
| 4,000 hours | 中期大修 | Replace all piston rings, rider bands, and valve plate assemblies |
| 8,000 hours | 大修 | Inspect crankshaft journals, measure main bearing clearances, replace bearings if >0.08 mm |
The oil-free design of the LW-16.5/13 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 only consumable wear items are the 聚四氟乙烯活塞环和活塞环带, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions. At 1.30 MPa discharge pressure, ring wear rates are slightly elevated compared to low-pressure operation, and we recommend adhering to the 4,000-hour replacement interval for optimal reliability.
合规与安全认证
The LW-16.5/13 nitrogen compressor is designed, manufactured, and tested to meet the following international standards and regulatory frameworks:
ASME BPVC 第 VIII 部分第 1 部分、GB 150-2011、PED 2014/68/EU 模块 A
IEC 60034-1（IE3能效）、IEC 60204-1、ISO 12100机械安全
ISO 8573-1 0 级（含油量），经 TÜV 莱茵独立测试
ISO 9001:2015 (Quality Management), ISO 14001:2015 (Environmental Management)
Nitrogen is classified as a simple asphyxiant gas. At 1.30 MPa discharge pressure, the risk of rapid nitrogen release and oxygen displacement is significantly elevated. All LW-16.5/13 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas. Ventilation systems must be engineered to maintain ambient oxygen concentrations 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 nitrogen piping must be designed, fabricated, and inspected in accordance with ASME B31.3 Process Piping standards. All personnel working on high-pressure nitrogen systems must be trained in pressure safety and asphyxiation hazards.
性能与效率分析
The LW-16.5/13 achieves a specific power consumption of approximately 9.70 kW per m³/min of nitrogen delivered at 1.30 MPa discharge pressure. This specific power reflects the thermodynamic penalty associated with the high pressure ratio required to reach 1.30 MPa from near-atmospheric inlet conditions. While higher than low-pressure compressors, this efficiency 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, and hydraulic gas boosters (often used for high-pressure nitrogen) can exceed 15 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the LW-16.5/13’s efficiency advantage versus less efficient alternatives yields approximately 66,000–132,000 kWh of annual energy savings. At $0.08/kWh, this represents $5,280–$10,560 in direct electricity cost reduction per year. However, the primary economic justification for the LW-16.5/13 typically stems from the elimination of oil-related consumables and the avoidance of downstream purification equipment rather than marginal energy savings. The total cost of ownership for high-pressure nitrogen compression is reduced by an estimated 25–35% over a 10-year operational life when compared to oil-lubricated alternatives requiring extensive downstream purification.
The oil-free design also eliminates the energy penalty of downstream oil-removal equipment. A typical oil-lubricated high-pressure compressor requires multi-stage coalescing filters, activated carbon adsorbers, and continuous oil monitoring instrumentation that collectively consume 4–6% of the compressor’s power output. The LW-16.5/13’s native oil-free certification removes this parasitic load entirely, improving effective system efficiency and reducing electrical infrastructure requirements.
定制化和OEM能力
We offer comprehensive customization options to adapt the LW-16.5/13 to specific process requirements, site conditions, and integration constraints:
- Skid-Mounted Turnkey Packages: 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. Factory pre-testing of all systems reduces field commissioning time by approximately 60% and minimizes startup risks.
- 危险区域配置： ATEX Zone 2 and IECEx compliant motor and electrical enclosures are available for installations in chemical facilities where explosive atmospheres may occasionally be present. Integrated gas detection and automatic ventilation interlocks can be incorporated into the control system.
- 高级过程控制： 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 and reduce mechanical stress during startup.
- High-Pressure Package Options: Integrated high-pressure nitrogen receivers (up to 2.0 m³ at 1.6 MPa), pressure regulation stations, and distribution manifolds can be supplied on the common skid, creating a complete high-pressure nitrogen supply system.
- 环境保护： 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 from 84 dB(A) to 70 dB(A) at 1 meter.
- OEM & Private Label: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators.
可提供自定义配置 最小起订量 1 件. Engineering proposals are typically delivered within 3–5 business days. Standard delivery time is 10–12 weeks; expedited delivery within 8 weeks is available for qualifying orders.
Case Study: Chemical Plant Reactor Inerting System Upgrade
客户： A specialty chemical manufacturer in Eastern China operating batch reactors for pharmaceutical intermediates
挑战： The client’s existing nitrogen supply relied on a bank of high-pressure cylinders (15 MPa) manifolded together to feed reactor inerting systems at 1.20 MPa. Monthly cylinder consumption reached 120 cylinders, with handling labor, delivery scheduling, and cylinder rental fees consuming $180,000 annually. The cylinder supply was also unreliable during peak demand periods, causing production delays. Additionally, residual oil contamination from the cylinder filling station was detected in the nitrogen stream, compromising catalyst performance in hydrogenation reactors.
解决方案： We supplied an LW-16.5/13 oil-free nitrogen compressor paired with a small VPSA nitrogen generator (99.9% purity, 18 m³/min) on a common skid. The LW-16.5/13 compresses the VPSA product to 1.30 MPa, feeding the reactor inerting header directly. A 1.5 m³ high-pressure receiver was integrated on the skid to buffer demand fluctuations during batch reactor cycles. The oil-free design eliminated catalyst contamination, while the on-site generation eliminated cylinder dependency.
Quantified Results After 18 Months:
- Nitrogen supply cost: Reduced by 58% ($180,000 to $75,600/year) versus cylinder supply
- Cylinder handling labor: Eliminated completely, saving 480 man-hours/year
- Catalyst contamination incidents: Reduced from 3 per year to zero, improving batch yield consistency
- Production delays due to gas shortage: 淘汰, improving on-time delivery from 92% to 99.5%
- Nitrogen purity: Consistently >99.9% with oil content <0.01 mg/m³, achieving ISO 8573-1 Class 0
- Payback period: 2.1 years based on gas cost and labor savings alone
“The LW-16.5/13 has eliminated our cylinder dependency and improved our process reliability dramatically. The oil-free certification gives us confidence that our catalysts are protected, and our production schedule is no longer hostage to gas delivery trucks.” — Plant Manager, Specialty Chemical Facility
常见问题解答及选购指南
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