Methane Compressor

Methane (CH₄) is the main component of natural gas and coalbed methane. It has a molecular weight of 16.04, a density of 0.717 kg/m³ under standard conditions, and is lighter than air so it tends to accumulate at high points after leakage. Its critical temperature is as low as -82.6°C, and its boiling point is -161.5°C, making the risk of liquefaction under conventional compression extremely low; however, special attention is required in high-pressure cryogenic processes (such as LNG). Methane is highly flammable and explosive, with an explosion limit in air of 5% to 15%. Its safety classification is Ex d IIB T4, imposing strict requirements on equipment sealing and explosion-proof performance. In industry, methane runs through the entire LNG chain—from raw gas boosting, liquefaction and storage, to gasification and distribution—and it is also an important chemical feedstock for ammonia synthesis and methanol production, as well as being used as a high-purity gas in the food and pharmaceutical sectors.

DIAPHRAGM COMPRESSOR

PISTON COMPRESSOR

Methane Diaphragm Compressor Advantages

01

Ultimate Purity and Absolute Safety:

The static sealing structure of the diaphragm chamber achieves physical isolation between the gas and lubricating oil, ensuring the purity of compressed methane is as high as 99.999%, while completely eliminating gas leakage during operation. This perfectly matches the flammable and explosive nature of methane, providing the highest level of protection for chemical-grade methane, laboratory research, and safety-sensitive areas.
02

High Pressure Capability and Wide Adaptability:

A single stage can achieve a high compression ratio, with a maximum discharge pressure of up to 100 MPa. It can meet ultra-high-pressure requirements ranging from CNG filling and high-pressure bottling to special chemical processes. Its corrosion-resistant material options also allow it to handle methane gas sources containing trace impurities.

Methane Diaphragm Compressor Design Points

01

Diaphragm Safety Monitoring and Material Upgrade:

A three-layer diaphragm structure must be configured with an integrated rupture monitoring and alarm system to ensure immediate interlock shutdown upon diaphragm failure, preventing oil-gas mixing. All flow-wetted parts must be made of 316L stainless steel or a higher-grade material and undergo strict degreasing and cleaning to guarantee gas purity and material compatibility.
02

Precise Thermal Management and Leak Prevention Design:

The discharge temperature of each stage must be strictly controlled, typically not exceeding 120–135°C, to prevent the impact of high temperature on diaphragm life and sealing materials. All static sealing points in the gas path system must adopt metal seals or high-performance sealing elements. Nitrogen purging interfaces must be provided for purging before startup and maintaining pressure after shutdown to prevent the formation of explosive mixtures.
03

Integrated Safety Interlock System:

Methane-specific combustible gas detectors must be installed within the compressor skid scope and interlocked with the main engine Emergency Shutdown (ESD) system and emergency ventilation system. Dual alarms and shutdown interlocks must be set for pressure and temperature parameters to establish an active safety protection system.

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

High Pressure Methane Diaphragm Compressor

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)

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-52/40-56	500	52	4	5.6	1200×700×1100	900	3
2	GZ-15/10-12	500	15	1	1.2	1200×700×1100	900	3
3	GZ-150/15-40	3000	150	1.5	4	2030×1045×1700	2500	30
4	GV-10/16-250	1000	10	1.6	25	1400×900×1200	1000	7.5
5	GV-10/（15-20）-160	1000	10	1.5-2	16	1400×900×1200	1000	7.5
6	GV-30/4-250	1000	30	0.4	25	2400×1700×1300	3000	15
7	GL-20/12-160	1000	20	1.2	16	2200×1800×1300	3000	7.5
8	GL-70/5-35	1500	70	0.5	3.5	2000×1800×1200	3000	15
9	GL-60/0.05-4	4000	60	0.005	0.4	2400×1800×1600	3000	15
10	GD-220/12-90	4000	220	1.2	9	3000×2000×1800	4000	37
11	GD-130/8-300	6500	130	0.8	30	3500×2300×1800	4500	45
12	GD-500/20-250	9000	500	2	25	3800×2300×2000	100000	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

Advantages of Methane Reciprocating Compressors

01

High Flow Rate and Economic Efficiency:

Reciprocating compressors, especially the balanced-opposed type (D-type), can deliver a wide capacity range from thousands to tens of thousands of cubic meters per hour with high volumetric efficiency. They are well-suited for large-flow, continuous industrial applications such as natural gas pipeline boosting, feed gas processing in liquefaction plants, and large gas-fired power plants, offering excellent economies of scale.
02

Wide Compression Ratio Range and Technical Maturity:

They have a broad pressure adaptation range, covering from medium pressure to ultra-high pressure (e.g., 25 MPa and above), with mature and reliable technical routes. Depending on the required purity level, lubricated, micro-lubricated, or oil-free designs can be adopted, providing proven solutions for complex operating conditions such as BOG recompression in large LNG receiving terminals and associated gas recovery in oil and gas fields.

Key Design Points for Methane Reciprocating Compressors

01

Oil-Free Lubrication and Interstage Cooling to Prevent Liquid Slugging:

To ensure methane purity and prevent lubricating oil from entering the process system, oil-free piston rings and packing made of PTFE or carbon composite materials should be used. Efficient interstage coolers and gas-liquid separators must be designed. Although methane has a low critical temperature and does not easily liquefy under normal conditions, this effectively controls the discharge temperature, reduces power consumption, and prevents liquid carryover or condensation of heavy components in the intake gas that could cause "liquid slugging."
02

Explosion-Proof Sealing and Buffer Isolation:

The drive motor and all electrical components must meet the Ex d IIB T4 explosion-proof classification. The piston rod packing system should be designed with a nitrogen buffer seal to direct trace amounts of process gas leakage to a safe vent or flare system, preventing combustible gas from entering the crankcase. For low-temperature BOG compressors, the distance piece must adopt an extended design and be equipped with nitrogen isolation facilities.
03

Pulsation Suppression and Vibration Control:

Due to the low density of methane, gas flow pulsation is likely to occur during compressor operation. Pulsation dampeners or surge bottles must be designed and installed near the suction and discharge ports of each stage. Pipeline vibration analysis should be performed in accordance with standards such as API 618 to ensure the piping system and foundation are stable, thereby ensuring long-term, safe, and stable operation of the equipment and reducing the risk of fatigue failure.

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

2.1

Actual volume flow (m3/min)

0.15

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-2.1/0.15-15	120	0.015	1.5	22
2	ZW-0.9/6-25	310	0.6	2.5	30
3	ZW-0.63/3-200	130	0.3	20	37
4	VW-10/8	600	Atm	0.8	75
5	VW-15/13	780	Atm	1.3	132
6	VW/20/8	1020	Atm	0.8	132
7	D-1.47/10-300	800	1	30	185
8	D-1.1/10-300	600	1	30	160
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