Description

DF-0.45/(8-10)-250 CNG Compressor

High-Pressure CNG Compressor for Natural Gas Compression & Industrial Gas Applications

The DF-0.45/(8-10)-250 CNG Compressor is a high-pressure reciprocating compressor designed for CNG compression, natural gas boosting, gas recovery, and industrial gas handling applications.

Engineered to handle natural gas containing approximately 96% CH₄, 3% CO₂, H₂S below 21 ppm, and moisture content of approximately 500–1000 ppm, the compressor provides reliable high-pressure gas compression for demanding operating environments.

The unit offers a nominal volume flow of approximately 0.45 m³/min, corresponding to around 200 Nm³/h at 0.9 MPa, with a design flow of approximately 0.35 m³/min. It operates with an inlet pressure range of 0.8–1.0 MPa.G, with 0.9 MPa.G as the design point, and provides an exhaust pressure of up to 25.0 MPa.G.

Driven by a 45 kW explosion-proof three-phase asynchronous motor, the compressor combines high-pressure compression capability with a compact skid-mounted configuration. Its integrated design makes it suitable for CNG filling stations, natural gas facilities, and selected industrial gas applications.

Key Technical Specifications

D-Type Symmetrical Balanced Compressor Structure

The DF-0.45/(8-10)-250 incorporates a D-type symmetrical balanced reciprocating structure designed for stable operation and reduced mechanical vibration.

The balanced arrangement helps distribute reciprocating forces across the compressor, supporting smooth operation during continuous compression duty.

The compressor incorporates:

• D-type symmetrical balanced configuration
• Reciprocating piston compression
• 3-stage differential compression
• Low-oil lubrication arrangement
• Natural cooling for cylinders
• Forced air cooling for the complete machine
• Integrated skid-mounted construction

This configuration is suitable for high-pressure CNG and natural gas compression where operational stability and equipment durability are important.

High-Pressure Oil-Controlled Compression System

The compressor incorporates a low-oil lubrication design intended to minimize the transfer of lubricating oil into the compression cylinders.

A high-efficiency post-mounted oil separator is provided to help control oil carryover from the compressed gas stream. Under the specified operating conditions, the gas oil content can be controlled to approximately 8 ppm according to the supplied technical specification.

This arrangement helps maintain cleaner compressed gas while supporting reliable operation of the compressor.

Three-Stage Differential Compression

The DF-0.45/(8-10)-250 utilizes a three-stage differential compression configuration to progressively increase natural gas pressure.

Multi-stage compression can provide better management of compression ratios and discharge temperatures compared with attempting to achieve the complete pressure increase in a single stage.

The configuration is designed to compress natural gas from approximately 0.8–1.0 MPa.G inlet pressure to an exhaust pressure of up to 25.0 MPa.G.

Robust Compressor Construction

The compressor crankcase is manufactured from HT250 gray cast iron, providing a rigid structural foundation for the crankshaft, connecting rods, and other moving components.

The crankcase incorporates provisions for:

• Lubrication
• Oil drainage
• Temperature monitoring
• Maintenance access

The high-pressure cylinder surfaces incorporate ion nitriding treatment to increase surface hardness and help reduce internal wear.

Piston components are equipped with guide rings and self-aligning arrangements designed to support accurate piston movement and reduce gas leakage during operation.

High-Performance Materials & Components

The compressor incorporates selected materials for major mechanical components, including:

• Crankshaft: 45#
• Connecting Rod: 40Cr
• Three/Four-Stage Cylinders: 40Cr
• Piston Rings: PEEK
• Packing Components: PEEK

These material selections are intended to provide durability and reliable operation under demanding reciprocating compression conditions.

Service Life & Maintenance

The compressor is designed with a focus on reducing maintenance frequency and extending the service life of critical components.

According to the supplied technical specifications:

• Piston rings, packing, and valves have a service life of at least 6,000 operating hours
• Connecting rod bearings and crankshafts have a service life of at least 30,000 operating hours

Actual service life depends on operating conditions, gas composition, maintenance practices, lubrication, operating pressure, and other site-specific factors.

Automated Control System

The DF-0.45/(8-10)-250 can be equipped with an automated control system incorporating a Siemens S7-200 PLC and 7-inch Weinview colour touchscreen.

The control system can provide monitoring and management of key operating parameters, helping reduce manual intervention and improve operational consistency.

The system can be configured for monitoring and control of:

• Compressor operating status
• Pressure
• Temperature
• Cooling system
• Lubrication parameters
• Alarm conditions
• Shutdown conditions
• Compressor protection functions

Remote Monitoring & DCS Integration

For projects requiring integration with a plant control system, the control cabinet can be configured with an RS485 communication interface supporting MODBUS-RTU.

This allows the compressor control system to be integrated with a customer’s DCS or other supervisory control system, subject to the final project communication architecture.

Remote monitoring can help operators access compressor operating information without requiring continuous local intervention.

Explosion-Proof Drive System

The compressor is powered by a 45 kW YBX3-280M-8 explosion-proof three-phase asynchronous motor.

An explosion-proof drive configuration is suitable for applications where the compressor operates in environments requiring appropriate electrical equipment for potentially hazardous gas atmospheres.

The motor starting arrangement can also incorporate a soft starter, where specified, to reduce starting current impact and provide smoother motor acceleration.

Low-Noise Cooling System

The compressor uses a combination of cylinder cooling and forced-air cooling to manage operating temperatures.

Large-diameter, low-speed fans can be used to provide effective airflow while helping control operational noise.

This makes the package suitable for industrial environments where equipment noise levels are an important consideration.

Skid-Mounted Integrated Design

The main and auxiliary equipment can be installed on a common structural skid, creating an integrated compressor package.

The skid-mounted design provides several practical advantages:

• Compact equipment arrangement
• Simplified transportation
• Reduced site assembly requirements
• Pre-integrated piping and equipment
• Easier installation
• Centralized equipment layout
• Simplified project coordination

The approximate package dimensions are 5500 × 3200 × 2700 mm, with an approximate overall weight of 6 tonnes.

Final dimensions and weight should be confirmed against the project-specific configuration.

CNG & Natural Gas Applications

The DF-0.45/(8-10)-250 can be used across a range of natural gas and industrial gas applications.

CNG Filling Stations

The compressor can be integrated into CNG filling station compression systems for high-pressure natural gas compression and downstream storage or dispensing applications.

Natural Gas Pipeline Gas Extraction

The compressor can be used in selected systems requiring natural gas extraction or boosting from pipeline networks, subject to the required operating conditions.

Combustible Gas Recovery

The unit can be applied to systems designed for recovery and compression of combustible gases for subsequent storage, transfer, or processing.

Pharmaceutical & Brewing Industries

Compressed gas systems can be integrated into selected agitation and process-gas applications within pharmaceutical and brewing facilities.

Chemical Industry

The compressor can support pressurized gas transportation and transfer applications in chemical processing environments.

Food & Beverage Industry

Compressed gas can be used in selected blow-moulding and bottle-manufacturing processes, depending on the gas and process requirements.

Machinery Manufacturing

The compressor can support compressed-gas applications such as component and parts cleaning or dust removal where appropriate.

Customizable Configuration

The DF-0.45/(8-10)-250 can be configured according to project-specific operating and environmental conditions.

Customization options may include:

• Gas flow capacity
• Inlet pressure
• Discharge pressure
• Lubricating oil specification
• Cooling configuration
• Motor starting method
• Control system
• Communication interface
• Skid arrangement
• Installation configuration
• Equipment identification and nameplate requirements
• Customer branding and documentation

Lubricating Oil Selection

Lubricating oil selection can be adapted to ambient operating conditions. The supplied specification identifies:

• L-DAB150 for ambient temperatures above 5°C
• L-DAB100 for ambient temperatures below 5°C

The final lubricant specification should be confirmed with the compressor manufacturer and according to actual operating conditions.

Patented Compressor Technology

The supplied technical information identifies several patented design elements associated with the compressor, including:

• Piston rod thread protective sleeve – ZL 2017 2 1907021.7
• Piston ring support device – ZL 2018 2 0294776.2
• Symmetrical balanced compressor piston arrangement – ZL 2017 2 190177.0

These design features are intended to support compressor durability, piston operation, and maintenance performance.

Key Advantages

High-Pressure Performance

Designed for natural gas compression from approximately 0.8–1.0 MPa.G inlet pressure to up to 25.0 MPa.G discharge pressure.

Reliable Operation

The symmetrical balanced configuration and robust mechanical construction support stable compressor operation.

Integrated Skid Package

Main and auxiliary equipment are integrated onto a common skid to simplify transportation, installation, and commissioning.

Automated Control

PLC-based controls and touchscreen monitoring reduce manual intervention and provide centralized compressor operation.

Remote Communication

RS485/MODBUS-RTU communication can facilitate integration with plant DCS systems.

Flexible Application

Suitable for CNG stations as well as selected natural gas recovery, transfer, and industrial gas applications.

Customizable Configuration

The compressor package can be configured according to gas conditions, pressure requirements, cooling requirements, control architecture, and installation conditions.

Aegis Projects – CNG & Natural Gas Compression Solutions

Aegis Projects Technology Pvt. Ltd. provides engineered solutions for CNG compressor systems, natural gas compression, compressor skids, industrial gas systems, automation, instrumentation, and turnkey project applications.

Our team can assist with compressor package integration, skid configuration, piping, instrumentation, electrical systems, PLC controls, safety systems, and project-specific engineering requirements.

For a DF-0.45/(8-10)-250 CNG Compressor or a customized high-pressure natural gas compression system, share your required gas composition, flow rate, inlet pressure, discharge pressure, operating conditions, and installation requirements with Aegis Projects.

Aegis Projects Technology Pvt. Ltd. — Engineered Compression & Industrial Automation Solutions.

Technical Parameter