Acetylene Compressor

Acetylene (C₂H₂) is a critical raw material in basic chemical processing and metal cutting/welding, yet its hazards pose the most stringent challenges to compression equipment. With an extremely wide explosion limit (2.5%～80% in air), poor thermal stability, a minimum auto-ignition temperature of only 305°C, and a high tendency for decomposition explosions when in contact with metals such as copper and silver at elevated temperatures, an acetylene compression system must prioritize explosion-proof safety, strict temperature control, and material compatibility. Targeting these characteristics, our company offers specially designed diaphragm compressor and piston compressor solutions to ensure full-process safety and reliability from the gas source to the point of application.

DIAPHRAGM COMPRESSOR

PISTON COMPRESSOR

Acetylene Diaphragm Compressor Advantages:

01

Absolute Zero Media Contamination and Zero Leakage:

The core of the diaphragm compressor lies in its metal diaphragm, which completely isolates the compression chamber into a gas chamber and an oil chamber. For acetylene, this means 100% physical isolation between the lubricating oil system and the process gas, thoroughly eliminating the risk of oil molecules entering the acetylene gas stream and causing contamination, coking, or potential reactions. Simultaneously, the static seal structure fundamentally eliminates the possibility of external leakage from dynamic sealing points such as shaft seals, ensuring that the highly toxic and flammable acetylene gas does not escape, thereby meeting the strictest environmental and safety standards.
02

Intrinsically Safe Compression Process and Excellent Working Condition Adaptability:

The compression method, based on the reciprocating flexure of the diaphragm, involves no sliding friction pairs in contact with the gas, preventing the generation of local hot spots and sparks, and fundamentally reducing the risk of combustion and explosion. This model is insensitive to fluctuations in suction pressure and can easily achieve discharge pressures up to tens of megapascals. It is highly suitable for boosting from low-pressure acetylene sources to high-pressure synthesis or filling processes, providing stable output pressure with no loss of purity.

Key Design Points for Acetylene Diaphragm Compressors:

01

Top-Level Explosion-Proof Electrical Configuration and Multi-Layer Diaphragm Safety Monitoring:

All electrical equipment, including drive motors, instruments, and control components, must meet the explosion-proof requirements for IIC Class, T2 Group. A common explosion-proof rating is Ex d IIC T2, ensuring that the maximum surface temperature of the equipment does not exceed 300°C, far below the auto-ignition temperature of acetylene. A three-layer diaphragm structure is adopted, equipped with a diaphragm rupture pressure switch alarm and automatic shutdown interlock. Once the outer diaphragm ruptures, the abnormal pressure increase in the middle layer immediately triggers protection, preventing oil and gas from mixing.
02

Strict Temperature Control and Material Prohibitions:

The discharge temperature at each stage must be strictly controlled within a safe range, well below the decomposition temperature of acetylene under the actual operating pressure (approximately 305°C at atmospheric pressure, but significantly lower at elevated pressures). This is typically achieved by optimizing the compression ratio, enhancing inter-stage cooling, and employing air/water cooling systems, along with a high-high discharge temperature shutdown protection.

Strict material prohibitions must be enforced: Copper, silver, and their alloys are strictly forbidden for all parts in contact with acetylene, while mercury contamination should also be avoided. High-quality stainless steel is typically used for acetylene-contacting components and undergoes special degreasing and passivation treatment to remove processing residues and improve corrosion resistance.
03

Complete Safety Interlocks and System Protection:

In addition to diaphragm rupture and over-temperature protection, the system must integrate multiple safety interlocks such as low suction pressure, high discharge pressure, low lubricating oil pressure, and cooling system failure. Any abnormal parameter will trigger an alarm and automatic shutdown. The relief capacity of the safety valves must be strictly calculated to ensure rapid discharge in the event of overpressure. The relieved gas must be tightly sealed and routed to a safe flare or treatment system; local discharge is strictly prohibited. Before startup, the system must be thoroughly purged with an inert gas.

Certificate

MODEL SELECTION

Model G70Z/G95Z/G110Z/G130Z	Piston Stroke 70mm~130mm	Maximum Piston Force 10KN~30KN
Maximum Discharge Pressure 70Mpa	Flow Range 1~500Nm³/h	Motor Power 2.2KW~30KW
Crankshaft Speed 420rpm	Cooling Method Water Cooled/Air Cooled

Model G70V/G95V/G130V	Piston Stroke 70mm~130mm	Maximum Piston Force 10KN~30KN
Maximum Discharge Pressure 50Mpa	Flow Range 1~200Nm³/h	Motor Power 2.2KW~30KW
Crankshaft Speed 420rpm	Cooling Method Water-cooled / Air-cooled

Model G110L/G130L	Piston Stroke 110mm~130mm	Maximum Piston Force 20KN~40KN
Maximum Discharge Pressure 100Mpa	Flow Range 10~1000Nm³/h	Motor Power 7.5KW~90KW
Crankshaft Speed 420rpm	Cooling Method Water-cooled / Air-cooled

Model G110D/G130D/G150D/ G180D/G182D/G210D	Piston Stroke 110mm~210mm	Maximum Piston Force 20KN~160KN
Maximum Discharge Pressure 100Mpa	Flow Range 30~2000Nm³/h	Motor Power 22KW~200KW
Crankshaft Speed 420rpm	Cooling Method Water-cooled / Air-cooled

Diaphragm type compressor

Piston stroke 70mm

Flow(Nm3/h)

0.5

Inlet pressure(barg)

Outlet pressure(barg)

No.	Model	Cooling water	Flow	Inlet pressure	Outlet pressure	Dimensions L×W×H	Weight	Motor Power
No.	Model	(L/h)	(Nm³/h)	(MPa)	(MPa)	(≈mm)	(≈kg)	(kW)
1	GZ-5/0.5-8	500	5	0.05	0.8	1400×740×1240	650	2.2
2	GZ-17/5-25	1000	17	0.5	2.5	1500×800×1200	800	7.5
3	GZ-60/2.5-14	1000	60	0.25	1.4	2200×1800×1700	2800	11
4	GV-17/5-25	800	17	0.5	2.5	1500×800×1200	800	5.5
5	GV-18/0.7-23	1000	18	0.07	2.3	1600×776×1080	900	7.5
6	GV-48/4-25	800	48	0.4	2.5	1588×768×1185	980	11
7	GL-25/15	1000	25	Atmospheric	1.5	2200×1200×1300	1600	7.5
8	GL-30/10	1000	30	Atmospheric	1	2200×1200×1300	2000	11
9	GL-100/4.5-14	2000	100	0.45	1.4	2400×1300×1300	3000	18.5
10	GD-150/0.2-3	4000	150	0.02	0.3	3200×1800×1600	4000	18.5
11	GD-250/0.2-15	8000	250	0.02	1.5	3600×2300×1800	6000	75
12	GD-900/3-15	7000	900	0.3	1.5	4800×4000×2200	16000	75

The equipment size and weight are for reference only, and the final design shall prevail.

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CASE STUDY

Russia
UNITED STATES
Spain
Kazakhstan

Acetylene Piston Compressor Advantages:

01

High Reliability Oil-Free Operation under Large Flow:

By utilizing self-lubricating materials for piston rings, rider rings, and packing, the piston compressor can achieve true oil-free lubrication within the cylinder, completely preventing lubricating oil from entering the acetylene gas path. This meets the extremely high gas purity requirements of processes such as chemical synthesis. The mature reciprocating structure ensures excellent stability and long service life under continuous high-load operation.
02

Strong Pressure Adaptability and Modular Design:

The piston compressor can flexibly configure the number of stages and cylinder diameters to accommodate a wide range of acetylene boosting requirements, from atmospheric pressure to high pressure. It is particularly suitable as core power equipment for large chemical plants. Its modular design facilitates maintenance and replacement of spare parts. The packing system can be designed with nitrogen purging and leakage collection, further enhancing safety and sealing.

Key Design Points for Acetylene Piston Compressors:

01

Oil-Free Lubrication Design with Strict Temperature and Speed Control:

The cylinder must adopt a fully oil-free lubrication design, and the average piston speed and compression ratio must be strictly controlled to prevent overheating of the friction pairs. A strict upper limit must be set for the discharge temperature, supplemented by efficient inter-stage and after-coolers. Temperature monitoring points must cover the discharge ports of each stage and be interlocked with a high-high shutdown mechanism. This is a core measure to prevent the thermal decomposition of acetylene.
02

Comprehensive Explosion-Proof and Material Safety Design:

The drive motor and all on-site electrical instruments must meet explosion-proof certifications of Ex d IIC T2 or higher. For all parts in contact with acetylene, such as the frame, cylinders, and piping, the use of alloys with a copper content exceeding 70% is strictly prohibited. The standard configuration is carbon steel or stainless steel, and the material compatibility of sealing elements must be verified. Transmission components, such as belts, must be made of anti-static materials, and protective covers must be manufactured from non-sparking materials.
03

Multi-Level Sealing and Integrated Safety System:

A multi-stage packing seal should be adopted, optionally with a nitrogen buffer seal system to dilute any potentially leaked acetylene with nitrogen and route it to a safe discharge point. The safety interlock system must integrate vibration monitoring, bearing temperature, cooling water flow/temperature, lubricating oil pressure, and gas concentration detection. The system must be preset with nitrogen purge connections to ensure thorough replacement of air or acetylene within the system before startup and after maintenance. The discharge piping from safety valves must be independent and routed to a safe area.

Certificate

MODEL SELECTION

Z Type

V / W Type

M Type

D Type

Piston stroke 80mm, 95mm	Piston force 10KN～25KN
Power 7.5KW-55KW	Number of cylinder banks 1/2
Crankshaft speed 740 rpm, 980 rpm	Number of compression stages 1/2/3/4
Drive mode Electric motor, diesel engine, natural gas engine

Piston stroke 92mm, 95mm, 105mm, 120mm	Piston force 25KN, 45KN, 65KN
Number of compression stages 1/2/3/4	Number of cylinder banks 2/3/4
Crankshaft speed 740 rpm, 980 rpm	Power 15KW-220KW
Drive mode Electric motor, diesel engine, natural gas engine

Piston stroke 92mm~315mm	Piston force 45KN~660KN
Number of compression stages 1/2/3/4	Number of cylinder banks 4
Crankshaft speed 300rpm~980rpm	Power 160KW-3000KW
Drive mode Electric motor, diesel engine, natural gas engine

Piston stroke 92mm~315mm	Piston force 25KN~200KN
Number of compression stages 1/2/3/4	Number of cylinder banks 2
Crankshaft speed 300rpm~980rpm	Power 30KW-1000KW
Drive mode Electric motor, diesel engine, natural gas engine

Vertical type

Oil-free / F: Air-cooled

0.6

Actual volume flow (m3/min)

Inlet pressure(barg)

Outlet pressure(barg)

S/N	Model	Flow	Inlet pressure	Outlet pressure	Motor power
S/N	Model	(Nm³/h)	(Mpa)	(MPa)	(kW)
1	ZW-0.6/2-25	90	0.2	2.5	30
2	ZW-1.5/1-12	180	0.1	1.2	22
3	ZW-1.4/2-20	250	0.2	2	37
4	VW-3/20	165	0	2	37
5	VW-4/20	220	0	2	45
6	VW-5/20	285	0	2	55
7	D-1.47/10-25	800 ~ 950	1-1.2	2.5	45
8	D-1.1/10-25	600-730	1-1.2	2.5	45
9	DW-30/16 - 20-30	27000	1.6-2.0	3	900
10	MW-154/6	10500	0.05	0.6	1100
11	MW-6/15-21	6000	1.5-2.0	2.1	185
12	M-40/3-7	9000	0.3	0.7	450