Mixed Gas Compressor

A Gas Mixture is not a single gas but a combination of various gases such as hydrogen, carbon monoxide, methane, and carbon dioxide mixed in specific proportions. It is widely used in applications such as chemical synthesis feedstock gas, oil and gas field associated gas recovery, and electronic protective gases. Compared to single-component media, the explosion hazard, corrosiveness, and thermodynamic properties of gas mixtures change dynamically with the composition, imposing higher requirements on compressor selection and safety design. The primary principle of its safety design is that it must be based on an accurate gas composition analysis report, identifying the most hazardous single component as the benchmark for explosion-proof, material, and process design. Furthermore, at the stoichiometric ratio, the maximum explosion pressure of a gas mixture can reach 7 to 8 times the initial pressure. Therefore, rigorous system design based on the hazardous component is critically important.

DIAPHRAGM COMPRESSOR

PISTON COMPRESSOR

Gas Mixture Diaphragm Compressor Advantages:

01

Zero Leakage Guarantee & Component Integrity:

The metal diaphragm completely isolates the process gas from the lubricating oil, achieving 100% oil-free operation and zero external leakage. This is crucial for preventing the accumulation of leaked flammable or explosive gas mixtures and for maintaining the specified component ratio of the mixture without oil contamination or air dilution, fundamentally eliminating safety risks caused by leakage.
02

Excellent Material and Media Adaptability:

The wetted parts of the diaphragm head (such as the diaphragm and cavity) can be custom-selected for materials based on the most corrosive or reactive components in the gas mixture, for example using 316L stainless steel, Hastelloy, etc. This flexibility ensures long-term compatibility between the compressor and complex gas components, preventing premature diaphragm failure or gas contamination due to material corrosion.

Key Design Points for Gas Mixture Diaphragm Compressors:

01

Explosion-Proof and Electrical Design Based on the Most Hazardous Component:

The explosion-proof rating of the electrical system must be determined based on the component with the highest gas group classification and the lowest auto-ignition temperature in the mixture. All motors, instruments, and junction boxes must meet the corresponding explosion-proof certifications. Additionally, the control cabinet must integrate a combustible gas concentration detector to monitor the environment around the compressor, interlocking with emergency ventilation when the concentration exceeds the limit.
02

Strict Temperature Control and Diaphragm Protection:

The discharge temperature is critical for preventing gas thermal decomposition or diaphragm overheating. The design must employ efficient multi-stage compression and inter-stage cooling systems to keep the final discharge temperature within a safe range. A diaphragm rupture monitoring system is standard; failure of any diaphragm layer will immediately trigger an alarm and shutdown, preventing gas from entering the oil side or oil from entering the process system.
03

System Safety Interlocks Targeting Gas Mixture Characteristics:

In addition to conventional oil pressure, water pressure, and pressure interlocks, special attention must be paid to the stability of the inlet gas composition. If the process permits, an online gas analyzer can be recommended to monitor changes in the concentration of key components. The system must be equipped with inert gas (e.g., nitrogen) purge connections for pre-startup purging and post-shutdown pressure holding/sealing, preventing air ingress that could form explosive mixtures or cause undesired chemical reactions.

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)

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-18/5-12	500	18	0.5	1.2	1000×800×1100	800	5.5
2	GZ-30/21-60	500	30	2.1	6	1100×800×1100	800	7.5
3	GZ-22/8-30	1000	22	0.8	3	1200×800×1100	800	11
4	GV-20/6-150	1000	20	0.6	15	1400×800×1100	900	11
5	GV-118/40-55	1000	118	4	5.5	1400×800×1100	1000	11
6	GV-160/10-30	2000	160	1	3	2600×1800×1600	3000	18.5
7	GL-55/3	1000	55	Atmospheric	0.3	2200×1800×1600	2800	11
8	GL-130/0.5-1	1500	130	0.05	1	2300×1800×1600	2800	11
9	GL-60/1-25	2000	60	1	2.5	2300×1800×1600	2800	22
10	GD-200/3-61	4500	200	0.3	6.1	3800×2300×1800	6000	45
11	GD-1000/20-120	10000	1000	2	12	4200×3200×2200	12000	132
12	GD-950/12-126	15000	950	1.2	12.6	4200×3500×2200	12000	160

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

Gas Mixture Piston Compressor Advantages:

01

Strong Flow Adaptability & High Cost-Effectiveness:

Piston compressors have a wide range of single-unit displacement, capable of meeting gas mixture processing needs from hundreds to tens of thousands of cubic meters per hour. When handling industrial gas mixtures with relatively stable compositions and large flow rates, their investment cost and operating energy efficiency are often more advantageous, making them particularly suitable as core boosting equipment on the main process line.
02

Flexible Structural Design & Maintenance Convenience:

The number of stages, cylinder diameter, and rotational speed can be flexibly configured based on the pressure and flow requirements of the gas mixture. For mixtures containing dust or trace amounts of liquid, high-efficiency separation and filtration devices can be installed at the inlet. Its modular structure also makes routine maintenance and replacement of wearing parts more convenient.

Key Design Points for Gas Mixture Piston Compressors:

01

Detailed Composition Analysis & Customized Design:

A complete gas mixture composition, component ratios, and possible variation ranges must be obtained before design begins. Based on this, the gas properties are calculated to precisely determine the cylinder volume, piston rod load, cooling requirements, etc. Material selection must be compatible with all components, with special attention paid to prohibited materials.
02

Critical Temperature Control & Piston Speed Limitation:

The discharge temperature at each stage must be strictly controlled to prevent lubricating oil carbonization (oil-lubricated) or seal failure (oil-free) due to overheating, or even gas decomposition. For light gas mixtures such as hydrogen-rich ones, the average piston speed should be limited to reduce frictional heat. The use of efficient cylinder jacket cooling and after-stage coolers is a necessary measure.
03

Multi-Level Safety Interlocks & Leakage Management:

The system must be equipped with comprehensive interlock shutdown protection, including high discharge temperature, low lubricating oil pressure, cooling water failure, low suction pressure, and high discharge pressure. For flammable and explosive gas mixtures, the piston rod packing system is the key focus for leakage prevention, typically using a nitrogen buffer seal to route leaked gas to a flare or recovery system. The crankcase should be equipped with positive pressure ventilation or inert gas sealing to prevent process gas from entering. The discharge of safety valves must be directed to a safe location.

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)	(MPag)	(MPag)	(kW)
1	ZW-2.1/0.15-15	120	0.015	1.5	22
2	ZW-0.9/6-25	320	0.6	2.5	30
3	ZW-0.63/3-200	120	0.3	20	37
4	VW-7.0/0.1-1.0	400	0.01	0.1	18.5
5	VW-2.0/2-36	300	0.2	3.6	45
6	VW-0.84/5-(150-200)	250	0.5	15-20	55
7	DW-13/18-22	12500	1.8	2.2	185
8	DW-6.7/38-53	14450	3.9	5.3	250
9	DW-0.85/10-150	480	1	15	90
10	MW-15/3.5-28	3000	0.35	2.8	400
11	MW-9.0/3-250	1500	0.3	25	500
12	MW-130/1.5	6800	0	0.15	250