Lenado
Intelligent
Equipment
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Industrial CNG Booster Compressor: High-Efficiency Gas Recovery & 25 MPa Refueling Systems
An industrial CNG Booster Compressor operates as the key pressure-amplification unit in compressed natural gas dispensing and storage networks. Designed to accept variable low-to-medium inlet pressures (0.5 MPa to 12.0 MPa) from pipeline spurs, storage cascades, or residual sub-station tanks, the unit compresses the gas stream to 20.0 MPa to 25.0 MPa for direct NGV vehicle refueling or high-pressure tube trailer dispatch. Configured for heavy-duty cycling and continuous 24/7 operation, the compact modular skid integrates inlet pulsation dampening, multi-stage reciprocating compression blocks, closed-loop thermal management, and explosion-proof automation panels.
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System Configurations & Architectural Layout
Modular skid architecture optimizes footprint constraints and ensures strict hazardous-area separation:
Inlet Buffer & Filtration Unit
Absorbs volumetric pressure pulsations from variable gas sources; incorporates 2-micron liquid and particulate knockout filters to protect compressor valves from moisture and debris carryover.
Multi-Stage Reciprocating Compressor Core
Vertical or balanced-opposed multi-cylinder blocks utilizing non-lubricated (PTFE-based) or minimal-lube cylinder designs to maintain zero oil contamination in the discharge gas.
Interstage Cooling & Separation
Shell-and-tube or fin-fan intercoolers positioned between compression stages equipped with automatic condensate drain traps to lower gas temperatures and condense moisture.
Electrical & Safety Control Skid
PLC-based safety-instrumented system housed in an explosion-proof enclosure (Ex d IIB T4 / Class I Div 1), monitoring suction pressure, discharge temperature, and crankcase vibration in real time.
Key Technical Parameters
|
Technical Parameter |
Specification |
|
Inlet Pressure (Pin) |
0.5–12.0 MPa; configurable according to source feed pressure |
|
Rated Discharge Pressure (Pout) |
25.0 MPa; adjustable setpoint up to 25.0 MPa |
|
Volumetric Capacity (Q) |
500–3,000 Nm³/h; customizable up to 5,000 Nm³/h |
|
Compression Stages |
2-stage or 3-stage reciprocating compression; determined according to compression ratio, CR ≤ 3.5 |
|
Cylinder Lubrication |
Non-lube or minimal-lube design with PTFE rings and zero oil carryover |
|
Drive Configuration |
Explosion-proof electric motor with VFD or natural gas engine drive |
|
Cooling Architecture |
Closed-loop forced-air fin-fan coolers or integrated water-glycol plate heat exchangers |
|
Electrical Protection |
Ex d IIB T4 / ATEX / IECEx certified; NEC Class I, Division 1 compliant |
Application Scenarios
CNG Daughter & Sub-Stations
Extracts low-pressure residual gas (down to 0.5 MPa) remaining in storage cylinders, maximizing overall gas utilization efficiency and eliminating venting losses.
Pipeline Pressure Boosting
Elevates fluctuating municipal medium-pressure pipeline gas to high-pressure storage thresholds required by fast-fill vehicle dispenser islands.
Industrial Gas Recovery
Recoups and recompresses boil-off or waste gas streams in industrial manufacturing plants for localized high-pressure pneumatic application.
Engineering Selection & Sizing Criteria
Specifying a booster compressor requires precise calculation of compression ratios and volumetric efficiency against variable suction feeds:
Suction Pressure Transients
Determine minimum and maximum inlet pressures. Wide suction swings require variable frequency drive (VFD) speed modulation to prevent 1st-stage cylinder overload or vacuum pull.
Volumetric Mass Flow Match
Calculate required flow rate (Nm3/h) based on peak refueling demand or target trailer evacuation windows (e.g., emptying a depleted storage cascade within a 60-minute cycle).
Thermal Limitation per Stage
Restrict single-stage compression ratios to prevent discharge temperatures from exceeding 140°C, protecting valve springs and O-ring elastomeric seals.
Duty Cycle Frequency
Account for start-stop frequency in retail fueling environments; continuous duty configurations prevent thermal fatigue on crankshafts and connecting rods.
Manufacturing, Materials & Quality Control
Crankcases & Frames
Cast from high-strength ductile iron (QT400-15 / EN-GJS-400-15) processed on CNC boring mills to ensure rigid alignment and eliminate dynamic deflection under full rod load.
Cylinders & Liners
Manufactured from forged alloy steel with induction-hardened, replaceable internal cylinder liners finished to a controlled micro-surface roughness for optimal ring sealing.
Valves & Piston Rings
Heat-resistant stainless steel reed or plate valves matched with carbon-fiber-filled PTFE piston rings and rider bands, rated for over 6,000 operating hours prior to scheduled overhaul.
Pressure Boundary Testing
100% Non-Destructive Testing (NDT) via magnetic particle inspection (MT) on all high-pressure gas manifolds; hydrostatic testing conducted at 1.5 times MAWP.
Customization & Engineering Integration Support
Skid Enclosures
Weatherproof, sound-attenuating canopy options reducing operational noise levels to <= 75 dB(A) at 1 meter, complete with forced ventilation and gas leak detection sensors.
SCADA & PLC Integration
Siemens S7 or Allen-Bradley PLC architectures supporting Modbus, Profibus, or Ethernet/IP protocols for remote operational telemetry.
Dual-Pressure Switching
Automated electro-pneumatic switching valves allowing seamless transition between direct pipeline boosting and residual storage evacuation modes.
Factory Workshop
FAQ
Qingdao Lenado Intelligent Equipment Co., Ltd. is one of the most experienced CNG booster compressor manufacturers and suppliers in China. We have world-leading production equipment and strong manufacturing capabilities. Please rest assured to wholesale bulk customized CNG booster compressor from our factory.
