ZW-2.1/8~25 Stickstoffkompressor – Ölfreier N2-Booster mit variablem Einlass für vielfältige industrielle Anwendungen

Engineered to deliver 2.1 m³/min at 2.50 MPa discharge pressure with 0.80 MPa inlet capability, the ZW-2.1/8~25 is a two-stage, single-row oil-free piston nitrogen compressor designed for nitrogen recycle, gas liquefaction booster duty, and high-pressure process applications with variable inlet conditions. Zero oil contamination, compact footprint, and optimized for continuous-duty operation.

Produktübersicht

Der ZW-2.1/8~25 nitrogen compressor represents a specialized solution within our oil-free piston compressor portfolio, distinguished by its variable inlet pressure capability ranging from 0.80 MPa up to the discharge pressure of 2.50 MPa. With a rated capacity of 2.1 m³/min und einem Auslassdruck von 2.50 MPa, this unit is purpose-built for nitrogen recycle applications, gas liquefaction booster circuits, and process systems where the inlet nitrogen is already partially compressed.

What makes the ZW-2.1/8~25 unique is its ability to accept inlet nitrogen at pressures up to 0.80 MPa, as indicated by the model designation “8~25” (representing inlet pressure range of 0.8 MPa to 2.5 MPa). This variable inlet capability eliminates the need for upstream pressure reduction when feeding from medium-pressure nitrogen headers, improving overall system efficiency and reducing pressure losses. The compressor can also operate as a conventional booster from atmospheric or low-pressure inlet when required, providing exceptional operational flexibility.

Der Kompressor verwendet einen two-stage, single-row (二列一级) configuration that is optimized for the moderate pressure ratio required when boosting from 0.80 MPa to 2.50 MPa. The single-row design simplifies the mechanical architecture while the two-stage arrangement ensures efficient thermodynamic performance and manageable discharge temperatures. Each stage features independent cooling, preserving the integrity of the PTFE sealing elements even under sustained operation.

Technical Specifications – ZW-2.1/8~25

* All specifications are rated at standard reference conditions (ISO 1217, Annex C). Actual performance may vary based on site altitude, ambient temperature, and inlet conditions. Capacity is specified at 0.80 MPa inlet pressure; actual capacity varies with inlet pressure.

Hauptmerkmale und technische Vorteile

1. Variable Inlet Pressure Capability (0.80–2.50 MPa)

The ZW-2.1/8~25 is uniquely engineered to accept inlet nitrogen across a broad pressure range from 0.80 MPa up to 2.50 MPa. This variable inlet capability is achieved through a robust valve design and cylinder sizing that accommodates varying suction densities without mechanical distress. When fed from a medium-pressure nitrogen header at 0.80 MPa, the compressor operates at its rated 2.1 m³/min capacity. When inlet pressure increases toward the discharge pressure, the compressor transitions into a pressure-maintaining or recycle mode with reduced power consumption. This flexibility eliminates the need for upstream pressure regulators or throttling valves that would waste energy and create noise, making the ZW-2.1/8~25 ideal for nitrogen recycle loops and process systems with variable upstream pressure.

2. Oil-Free PTFE Composite Sealing System

The ZW-2.1/8~25 utilizes a proprietary selbstschmierende Kolbenring- und Führungsbandbaugruppe manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. This material achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, ensuring the nitrogen stream remains completely free of oil contamination. At 2.50 MPa discharge pressure, the risk of oil vapor carryover is significantly magnified compared to low-pressure applications, making the oil-free design not merely advantageous but fundamentally essential. The PTFE formulation is rated for continuous operation at temperatures up to 180°C, ensuring reliable sealing integrity under the thermal stress of high-pressure compression.

3. Compact Single-Row Design for Space Efficiency

Der two-stage, single-row (二列一级) architecture of the ZW-2.1/8~25 is mechanically simpler than two-row designs, resulting in a more compact footprint and lower weight. At 1900 × 1296 × 2290 mm and 2.60 tonnes, the unit occupies less than 2.5 m² of floor space and can be transported and positioned using standard forklift equipment. The single-row configuration is well-suited for the moderate flow rate of 2.1 m³/min, where the inertial forces are manageable without the complexity of opposed-cylinder arrangements. This dimensional efficiency makes the ZW-2.1/8~25 particularly attractive for retrofit installations in existing process plants where machinery room space is limited.

4. Standardmäßiger 380-V-Industriemotorantrieb

The ZW-2.1/8~25 is driven by a 75 kW, 380 V, 50 Hz Drehstrom-Induktionsmotor conforming to IEC 60034-1 efficiency class IE3. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage switchgear or step-down transformers. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the unit accessible to a wide range of industrial facilities regardless of their electrical infrastructure scale.

Anwendungsszenarien

Nitrogen Recycle & Pressure Boosting Loops

In chemical process plants and gas treatment facilities, the ZW-2.1/8~25 serves as a nitrogen recycle compressor that recovers nitrogen from process vents and boosts it back to the required distribution pressure. The variable inlet capability is critical in these applications because the recovered nitrogen may be at any pressure between atmospheric and the process operating pressure. The compressor automatically adapts to the available inlet pressure, maintaining efficient operation across the full range. This recycle capability reduces nitrogen consumption by 30–50% compared to once-through nitrogen systems, delivering substantial operating cost savings and environmental benefits.

Gas Liquefaction Booster Duty

In small-scale nitrogen liquefaction plants, the ZW-2.1/8~25 nitrogen booster compresses nitrogen from the liquefier vaporizer or storage tank to the pressure required for distribution or further processing. The 2.50 MPa discharge pressure is sufficient for feeding high-pressure nitrogen into cryogenic storage systems or for driving nitrogen through heat exchangers and process equipment. The variable inlet capability allows the compressor to accept nitrogen directly from the liquefier at its operating pressure, eliminating the need for intermediate pressure reduction and improving overall liquefaction plant efficiency.

Medium-Pressure Header Pressure Maintenance

Industrial facilities with medium-pressure nitrogen distribution headers (0.80–1.50 MPa) often require a pressure maintenance compressor to compensate for demand fluctuations and pipeline losses. The ZW-2.1/8~25 can accept nitrogen directly from the header at its operating pressure and boost it to 2.50 MPa for high-pressure consumers or back into the header to maintain pressure during peak demand periods. This dual-mode operation—acting as both a booster and a pressure maintainer—provides exceptional operational flexibility and reduces the need for separate compressor units.

Laboratory & Pilot Plant High-Pressure Nitrogen

Research laboratories and pilot-scale chemical plants require high-pressure nitrogen for high-pressure reactor inerting, catalyst testing, and supercritical fluid applications. The ZW-2.1/8~25’s compact footprint and standard 380V electrical supply make it suitable for installation in laboratory utility rooms or pilot plant buildings. The 2.50 MPa discharge pressure is adequate for most laboratory high-pressure applications, while the oil-free certification ensures that nitrogen purity meets the stringent requirements of research-grade experiments and analytical instrumentation.

Material & Konstruktion

The ZW-2.1/8~25 is constructed from materials selected for high-pressure nitrogen compatibility, thermal resistance, and compact structural integrity:

Alle drucktragenden Bauteile sind gemäß den geltenden Normen konstruiert und gefertigt. ASME BPVC Abschnitt VIII Division 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2, and each completed pressure vessel is subjected to a hydrostatic pressure test at 1.5 times the maximum allowable working pressure (MAWP) for a minimum hold period of 30 minutes. High-pressure piping systems are fabricated from seamless SS316 with ANSI Class 600 flanged connections to ensure leak-tight integrity at 2.50 MPa operating pressure.

Installations- und Wartungsrichtlinien

Fundament- und Strukturanforderungen

The ZW-2.1/8~25 has a dry weight of 2.60 tonnes and a center of gravity approximately 750 mm above the baseplate. A reinforced concrete pad of 4–5 tonnes is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The single-row design generates moderate unbalanced forces that are easily managed with standard foundation practices. Minimum clearance requirements: 1.0 m on the non-drive side for valve access, 0.8 m on the drive side for motor maintenance, and 1.5 m overhead for crane access. Special attention must be paid to the high-pressure discharge piping, which must be properly supported and anchored to prevent vibration-induced fatigue at 2.50 MPa.

Auslegung des Kühlwassersystems

Der Kühlwasserbedarf beträgt ungefähr 10 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and intercooler in parallel. Given the high pressure ratio, the intercooler is critical for thermal management and must receive priority cooling water flow. Water quality specifications: pH 6.5–8.5, total dissolved solids < 500 mg/L, chloride content < 50 mg/L (to prevent SS316 tube corrosion), suspended solids < 30 mg/L, and total hardness < 300 mg/L as CaCO₃. A closed-loop cooling tower with side-stream filtration is recommended for sites with marginal water quality.

Wartungsplan

The oil-free design of the ZW-2.1/8~25 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. The primary consumable wear items are the PTFE-Kolbenringe und -Zündbänder, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions. The high-pressure valve plates may require more frequent inspection than low-pressure equivalents due to increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

Konformitäts- und Sicherheitszertifizierungen

The ZW-2.1/8~25 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Leistungs- und Effizienzanalyse

The ZW-2.1/8~25 achieves a specific power consumption of approximately 35.71 kW per m³/min of nitrogen at 2.50 MPa discharge pressure from 0.80 MPa inlet. This specific power figure reflects the thermodynamic reality of high-pressure compression from an already elevated inlet pressure. However, the true efficiency advantage of the ZW-2.1/8~25 lies in its ability to accept high-pressure inlet without energy-wasting pressure reduction. When compared to systems that throttle 0.80 MPa nitrogen down to atmospheric pressure before re-compressing to 2.50 MPa, the ZW-2.1/8~25 saves approximately 40–50% of the compression energy by utilizing the available inlet pressure directly.

Over an 8,000-hour annual operating cycle in a typical nitrogen recycle application, the ZW-2.1/8~25’s variable inlet capability yields approximately 120,000–180,000 kWh of energy savings compared to systems requiring upstream pressure reduction. At $0.08/kWh, this represents $9,600–$14,400 in annual electricity cost reduction. When combined with the elimination of oil-related consumables and the avoidance of downstream purification equipment, the total cost of ownership for nitrogen recycle compression is reduced by an estimated 30–40% over a 10-year operational life.

The absence of oil in the compression path is particularly valuable in recycle applications because any oil contamination would accumulate in the closed nitrogen loop, progressively degrading product quality and potentially contaminating process equipment. The ZW-2.1/8~25’s native oil-free design ensures that nitrogen purity is maintained indefinitely in recycle service.

Anpassungs- und OEM-Fähigkeiten

We offer flexible customization options to adapt the ZW-2.1/8~25 to specific site conditions and integration requirements:

• Kufenmontierte Pakete: Pre-assembled compressor, motor, coolers, instrumentation, and control panel on a structural steel skid with forklift pockets. Reduces field installation to electrical and cooling water connections only.
• Konfigurationen von Gefahrenbereichen: ATEX Zone 2 and IECEx compliant enclosures for petrochemical installations. Gas detection and automatic ventilation interlocks integrated into the control system.
• SPS- und Fernüberwachung: Optional Siemens LOGO! or S7-1200 PLC with HMI touchscreen, Ethernet connectivity, and SMS/email alarms. Compatible with Modbus TCP/IP for SCADA integration.
• Akustische Gehäuse: Compact IP54-rated sound enclosure reducing noise from 82 dB(A) to 68 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments.
• OEM & Private Label: Individuelle Lackierungen, Marken-Namensschilder und lokalisierte Dokumentation für Gasgerätehändler und Systemintegratoren.

Kundenspezifische Konfigurationen sind erhältlich bei Mindestbestellmenge: 1 StückTechnische Angebote werden üblicherweise innerhalb von 3–5 Werktagen erstellt. Die Standardlieferzeit beträgt 10–12 Wochen; für qualifizierte Bestellungen ist eine Expresslieferung innerhalb von 8 Wochen möglich.

Case Study: Chemical Plant Nitrogen Recycle System

Kunde: A specialty chemical manufacturer in Thailand operating batch reactors with nitrogen inerting

Herausforderung: The plant was consuming 8,000 Nm³/day of nitrogen for reactor inerting, with the spent nitrogen vented to atmosphere at 0.60 MPa after passing through the reactors. This once-through approach was costing $180,000/year in nitrogen purchase and represented a significant environmental waste stream. The plant wanted to recover and recycle the nitrogen but needed a compressor capable of accepting the variable outlet pressure from the reactors (0.40–0.80 MPa) and boosting it to 2.00 MPa for re-use in the high-pressure reactor feed system.

Lösung: Wir lieferten eine ZW-2.1/8~25 oil-free nitrogen compressor configured on a custom skid with integrated intercooler, aftercooler, and a Siemens LOGO! PLC control panel. The variable inlet capability allowed the compressor to accept nitrogen directly from the reactor vent header at whatever pressure was available, eliminating the need for upstream pressure regulation. A 1 m³ surge vessel was installed upstream to dampen pressure fluctuations from the batch reactor cycle.

Quantifizierte Ergebnisse nach 24 Monaten:

• Nitrogen consumption: Reduced by 65% (from 8,000 to 2,800 Nm³/day), saving $117,000/year
• Nitrogen vent emissions: Reduced by 65%, improving environmental compliance score
• Oil contamination in recycled nitrogen: <0.01 mg/m³, ensuring no process contamination
• Verfügbarkeit des Kompressors: 98.5% over 24 months, with only scheduled maintenance downtime
• Amortisationszeitraum: 1,8 Jahre based on nitrogen cost savings alone

“The ZW-2.1/8~25 has paid for itself in under two years. The variable inlet capability was the key feature that made this project feasible—we didn’t need to modify our reactor vent system or add pressure regulators. Our nitrogen costs have dropped by two-thirds and our environmental footprint has improved dramatically.” — Plant Manager, Specialty Chemical Facility

Häufig gestellte Fragen & Auswahlhilfe

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