DW-36/30 Nitrogen Compressor – High-Capacity Four-Stage Oil-Free N2 Booster for 3.00 MPa Industrial Process

Engineered to deliver 36 m³/min at 3.00 MPa discharge pressure, the DW-36/30 is a two-stage, four-row oil-free piston nitrogen compressor designed for ultra-high-pressure nitrogen injection, gas liquefaction, chemical synthesis, and demanding petrochemical process applications. Zero oil contamination, continuous-duty rated, and built for 24/7 industrial reliability at extreme pressure.

产品概述

这 DW-36/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor engineering, purpose-built for applications where both substantial flow capacity and extreme discharge pressure are non-negotiable requirements. With a rated capacity of 36 m³/min and an exceptional 3.00 MPa 排气压力, this unit occupies the ultra-high-pressure segment of our industrial nitrogen compressor portfolio, serving the most demanding process applications in the chemical, petrochemical, and gas processing industries.

What distinguishes the DW-36/30 from all conventional alternatives is its 完全无油压缩通道 combined with a four-stage compression architecture. 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 even at the extreme pressures where oil contamination risk is most acute. This intrinsic oil-free characteristic achieves ISO 8573-1 0级认证 natively, eliminating the need for downstream oil-removal filtration that would be technically challenging and economically prohibitive at 3.00 MPa.

The compressor architecture employs a two-stage, four-row (二列四级) configuration that is thermodynamically essential for achieving the 3.00 MPa discharge pressure from typical inlet conditions. The overall pressure ratio of approximately 30:1 to 60:1 is distributed across four compression cylinders, with each stage operating at a manageable pressure ratio. Three inter-stage coolers remove the substantial heat of compression, ensuring gas temperatures remain within safe operating limits and preserving the integrity of the PTFE sealing elements. The massive cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120,000 小时 under standard maintenance protocols.

Technical Specifications – DW-36/30

* 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. 适用于极端压力比的四级压缩

The DW-36/30 employs a four-stage compression architecture that is thermodynamically essential for achieving 3.00 MPa discharge pressure from typical inlet pressures of 0.05–0.10 MPa. The overall pressure ratio of approximately 30:1 to 60:1 is distributed across four compression cylinders, with each stage operating at a pressure ratio of approximately 2.5:1 to 3.5:1. This staged approach is critical because it limits the discharge temperature of each stage to below 150°C, preventing thermal degradation of the PTFE sealing elements and ensuring reliable long-term operation. Three high-efficiency shell-and-tube intercoolers between stages remove the substantial heat of compression, maintaining optimal thermodynamic efficiency throughout the compression path. Without four-stage compression, the discharge temperature would exceed 250°C, far beyond the safe operating limit of any oil-free sealing material.

2. Ultra-High-Pressure Oil-Free PTFE Sealing Technology

The DW-36/30 utilizes a proprietary 自润滑活塞环和导向带组件 manufactured from ultra-high-performance PTFE composites specifically formulated for extreme-pressure service. These rings are reinforced with high-modulus glass fiber and bronze particulates to achieve a coefficient of friction below 0.05 without any external hydrocarbon lubrication. At 3.00 MPa discharge pressure, the partial pressure of oil vapor would be approximately 100 times higher than at 0.30 MPa, making oil contamination not merely problematic but catastrophic for downstream processes. The DW-36/30’s native oil-free design achieves ISO 8573-1 Class 0 compliance without any downstream filtration, a feat that is technically impossible for lubricated compressors at this pressure level. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, with emergency capability to 200°C for brief periods.

3. Massive Reinforced Frame for High-Pressure Mechanical Loads

主框架由……铸造而成 GG25 gray cast iron with substantially reinforced wall sections, additional ribbing, and integral cooling water passages machined directly into the casting. The peak gas forces on the pistons at 3.00 MPa are approximately 10 times higher than in 0.30 MPa compressors, requiring a frame structure of exceptional rigidity. The two-row, four-cylinder arrangement provides inherent force balance, with opposed cylinders canceling first-order inertial forces. This mechanical symmetry reduces the unbalanced forces transmitted to the foundation by over 85%, permitting installation on a reinforced concrete inertia block of minimum 20 tonnes despite the massive peak loads. The crankshaft is forged from 42CrMo4 alloy steel, dynamically balanced to ISO 1940 G1.0 standards, and supported by five main bearing journals to distribute the extreme bearing loads.

4. Medium-Voltage Drive for Industrial-Scale Power

The DW-36/30 is driven by a 450 kW medium-voltage induction motor available in either 6kV or 10kV configurations, conforming to IEC 60034-1 efficiency class IE3. At 450 kW, a 380V motor would require approximately 800A of current, necessitating impractically large cables and switchgear. The medium-voltage drive eliminates these constraints, allowing direct integration into industrial medium-voltage distribution networks with manageable cable sizes and standard switchgear. This electrical architecture is essential for the DW-36/30’s power rating and reflects its positioning as a true industrial-scale compressor for large process plants.

应用场景

Ultra-High-Pressure Nitrogen Injection for Enhanced Oil Recovery

In oil and gas production, the DW-36/30 serves as a high-pressure nitrogen injection compressor for enhanced oil recovery (EOR) and miscible gas flooding operations. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into reservoir formations at depths up to 2,000 meters, where reservoir pressures typically range from 15–30 MPa. While the DW-36/30 does not reach reservoir pressure directly, it serves as the primary booster that feeds high-pressure injection pumps, reducing the overall compression energy required. The 36 m³/min capacity can support multiple injection wells simultaneously, making it suitable for field-scale EOR projects. The oil-free design is absolutely critical because any oil contamination would damage the reservoir formation, reduce permeability, and compromise oil recovery efficiency.

Chemical Synthesis & Ammonia Plant Nitrogen Feed

In ammonia synthesis plants and chemical manufacturing facilities, the DW-36/30 high-pressure nitrogen compressor provides the nitrogen feed gas at the elevated pressure required for catalytic synthesis reactions. The 3.00 MPa discharge pressure is suitable for feeding Haber-Bosch ammonia synthesis loops, methanol synthesis reactors, and other high-pressure chemical processes. The oil-free design prevents catalyst poisoning, which is a major concern in catalytic synthesis where even trace oil contamination can deactivate expensive catalyst beds and require costly shutdowns for catalyst replacement. The 36 m³/min capacity can supply the nitrogen requirements of medium-scale ammonia plants producing 300–500 tonnes per day.

Gas Liquefaction & Cryogenic Storage Pressure Boosting

In nitrogen liquefaction plants and cryogenic storage facilities, the DW-36/30 compresses nitrogen to the high pressure required for Joule-Thomson expansion liquefaction cycles and for maintaining pressure in cryogenic storage vessels. The 3.00 MPa discharge pressure is sufficient for Claude-cycle liquefiers and for driving nitrogen through the high-pressure side of recuperative heat exchangers. The oil-free design is essential because any oil contamination would freeze in the cryogenic sections of the liquefier, blocking heat exchanger passages and causing catastrophic cold-box failure. The 36 m³/min capacity supports liquefaction rates of 5,000–10,000 liters per hour of liquid nitrogen.

High-Pressure Pipeline Testing & Commissioning

In oil and gas pipeline construction, the DW-36/30 provides high-pressure nitrogen for hydrostatic testing, pneumatic strength testing, and pipeline commissioning. Nitrogen is preferred over air for pneumatic testing because it eliminates the explosion risk associated with oxygen-containing mixtures. The 3.00 MPa discharge pressure is suitable for strength testing pipelines rated to ANSI Class 300 and Class 600 pressure ratings. The 36 m³/min capacity allows rapid pressurization of large-diameter pipelines, reducing testing cycle time and accelerating project schedules. The oil-free design ensures that the tested pipeline is not contaminated with hydrocarbons that would require extensive cleaning before commissioning.

材料与施工

The DW-36/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, extreme mechanical stress resistance, and extended operational life:

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 或符合中国GB 150标准。所有焊接接头均按照ASME第五卷第二条进行100%射线探伤（RT），每个完工的压力容器均需进行1.5倍最大允许工作压力（MAWP）的水压试验，保持时间至少30分钟。高压管道系统采用无缝SS316不锈钢制造，并使用ANSI 900级法兰连接，以确保在3.00 MPa工作压力下具有良好的密封性。

安装和维护指南

基础及结构要求

The DW-36/30 has a dry weight of 13.00 tonnes and a center of gravity approximately 1,000 mm above the baseplate. Due to the massive peak gas forces at 3.00 MPa, a reinforced concrete inertia block of minimum 20 tonnes is required, mounted on heavy-duty elastomeric vibration isolators (natural frequency 5–7 Hz). The foundation must be engineered to support dynamic loads of 2.5× the static weight. Minimum clearance requirements: 2.0 m on the non-drive side for valve access, 1.5 m on the drive side for motor maintenance, and 2.5 m overhead for crane access during major overhauls. The compressor house must be designed for crane access capable of lifting 15-tonne loads for major maintenance events.

冷却水系统设计

冷却水需求量约为 80 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and three intercoolers in parallel branches, with priority flow to the intercoolers. Given the extreme pressure ratio, the intercoolers are absolutely critical for thermal management and must receive adequate cooling water flow at all times. Water quality specifications: pH 6.5–8.5, total dissolved solids < 400 mg/L, chloride content < 30 mg/L (to prevent SS316 tube corrosion in the high-pressure coolers), 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.

预防性维护计划

The oil-free design of the DW-36/30 dramatically reduces maintenance complexity 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 聚四氟乙烯活塞环和活塞环带, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions. However, the high-pressure stages (Stage 3 and 4) may experience accelerated wear due to the extreme mechanical stress, and more frequent inspection is recommended for these stages.

合规与安全认证

The DW-36/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

性能与效率分析

The DW-36/30 achieves a specific power consumption of approximately 12.50 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, where the work required increases dramatically with pressure ratio. Within the ultra-high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is competitive and significantly superior to diaphragm compressors, which are the primary alternative for oil-free service at this pressure level. For comparison, a diaphragm compressor of equivalent capacity would consume 18–25 kW/m³/min and cost 4–6 times more in capital expenditure.

Over a standard 8,000-hour annual operating schedule, the DW-36/30’s efficiency advantage versus diaphragm alternatives generates approximately 1,600,000–3,600,000 kWh of annual energy savings. At $0.08/kWh, this represents $128,000–$288,000 in direct electricity cost reduction per year. However, the primary economic justification for the DW-36/30 is typically the combination of high capacity, oil-free certification, and manageable capital cost that is impossible to achieve with alternative technologies at this pressure level. The 超高压氮气压缩的总拥有成本 is reduced by an estimated 40–55% over a 10-year operational life when compared to diaphragm compressor systems of equivalent capacity and purity.

The absence of oil in the compression path is absolutely critical at 3.00 MPa because oil contamination becomes exponentially more concentrated and more difficult to remove as pressure increases. At 3.00 MPa, the partial pressure of oil vapor would be approximately 300 times higher than at 0.30 MPa, making conventional oil-filtration technology completely ineffective. The DW-36/30’s native oil-free design eliminates this challenge entirely, ensuring that nitrogen purity is maintained at ISO 8573-1 Class 0 regardless of operating pressure or duration.

定制化和OEM能力

We offer comprehensive customization options to adapt the DW-36/30 to specific site conditions, integration requirements, and end-user specifications:

• Skid-Mounted Turnkey Packages: The compressor, motor, three intercoolers, aftercooler, high-pressure discharge piping, instrumentation, and control panel are pre-assembled on a heavy structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces commissioning time by 70%.
• 危险区域配置： ATEX Zone 2 and IECEx compliant motor and electrical enclosures for oil and gas installations. Integrated gas detection, fire suppression, and automatic ventilation interlocks incorporated into the safety PLC.
• 高级过程控制： Siemens S7-1500 or Allen-Bradley ControlLogix PLC with 15-inch HMI touchscreen, redundant safety systems, remote monitoring via OPC-UA, and seamless DCS/SCADA integration. Automatic load/unload, variable speed drive compatibility, and emergency isolation sequencing.
• 环境保护： C5-M marine-grade coatings for offshore installations; tropicalized electrical components for 55°C ambient; IP54-rated acoustic enclosures with noise reduction from 88 dB(A) to 75 dB(A) at 1 meter.
• OEM & Private Label: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and EPC contractors. Technical manuals, spare parts lists, and maintenance procedures in local languages.

可提供自定义配置 最小起订量 1 件. Engineering review and proposal generation typically require 7–10 business days. Standard delivery time is 16–20 weeks; repeat orders are delivered in 12–14 weeks from order confirmation.

Case Study: Ammonia Plant Nitrogen Feed Compressor Upgrade

客户： A fertilizer manufacturer in Indonesia operating a 400 tonne/day ammonia synthesis plant

挑战： The plant’s existing nitrogen feed compressor (oil-lubricated reciprocating, 22 years in service) was experiencing progressive oil carryover into the synthesis gas loop. Oil contamination was poisoning the iron-based ammonia synthesis catalyst, reducing conversion efficiency from 14.2% to 11.8% and increasing natural gas consumption by 8%. The catalyst replacement cost was $450,000 every 3 years instead of the designed 6-year interval. Additionally, the compressor’s 2.20 MPa discharge pressure was insufficient for the plant’s planned capacity expansion to 600 tonne/day, which required 2.80 MPa feed pressure.

解决方案： 我们提供了 DW-36/30 oil-free nitrogen compressor as the primary nitrogen feed compressor, configured on a custom skid with integrated three-stage intercooling, aftercooler, and a Siemens S7-1500 redundant safety PLC with full DCS integration. The 3.00 MPa discharge pressure provided adequate margin for the capacity expansion and allowed optimization of the synthesis loop pressure. The oil-free design eliminated catalyst poisoning risk entirely. A 10 m³ suction drum was installed upstream to buffer pressure fluctuations from the air separation unit.

Quantified Results After 36 Months:

• Ammonia synthesis catalyst life: Extended from 3 years to 7+ years, saving $450,000 per replacement cycle
• Natural gas consumption: Reduced by 6.2% due to restored catalyst activity, saving $280,000/year
• Oil content in synthesis gas: <0.01 mg/m³, completely eliminating catalyst poisoning
• Plant capacity: Successfully expanded to 600 tonne/day without additional compressor investment
• 计划外停机： Zero compressor-related events in 36 months

“The DW-36/30 has been the single most impactful equipment upgrade in our plant’s history. The elimination of oil contamination has restored our catalyst performance, reduced our natural gas bill by over a quarter-million dollars per year, and given us the confidence to expand our production capacity. The payback period was under 14 months.” — Chief Operations Officer, Fertilizer Manufacturing Plant

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