ZW-6/7 Stickstoffkompressor – Präzisions-Ölfreier N2-Booster für Prozessanwendungen im mittleren Druckbereich

Delivering 6 m³/min at 0.70 MPa discharge pressure, the ZW-6/7 is a two-stage, two-row oil-free piston nitrogen compressor engineered for precision process control, small-scale VPSA nitrogen boosting, and medium-pressure industrial gas distribution. Zero lubricant contamination, compact footprint, and optimized for reliable continuous-duty operation.

Produktübersicht

Der ZW-6/7 nitrogen compressor is a precision-engineered member of our oil-free piston compressor family, purpose-built for applications demanding both compact dimensions and elevated discharge pressure. With a rated capacity of 6 m³/min und einem Auslassdruck von 0,70 MPa, this unit occupies a unique niche between small laboratory compressors and large industrial boosters, serving process industries that require medium-pressure nitrogen in moderate flow quantities.

Unlike conventional lubricated compressors that necessitate elaborate downstream purification trains, the ZW-6/7 operates on a fully oil-free compression principle. Its PTFE composite piston rings and rider bands function without hydrocarbon lubricants, ensuring the nitrogen product stream maintains ISO 8573-1 Class 0 oil content certification. This inherent purity is indispensable for pharmaceutical process inerting, electronics soldering atmosphere control, and precision chemical synthesis where even trace oil contamination can compromise product integrity.

Der zweistufig, zweireihig (二列二级) architecture divides the compression workload across paired cylinders, with an inter-stage cooler maintaining gas temperatures within safe thermal envelopes. Despite its modest 6 m³/min capacity, the ZW-6/7 achieves a 0.70 MPa discharge pressure through optimized thermodynamic staging—delivering the pressure performance of larger units within a footprint of just 720 × 763 × 1475 mm and a weight of 0.80 tonnes.

Technical Specifications – ZW-6/7

* Alle Spezifikationen beziehen sich auf Standardreferenzbedingungen (ISO 1217, Anhang C). Die tatsächliche Leistung kann je nach Standorthöhe, Umgebungstemperatur und Einlassbedingungen variieren.

Hauptmerkmale und technische Vorteile

1. Ultra-Compact Vertical Design

The ZW-6/7 achieves exceptional space efficiency through a vertically oriented crankcase that minimizes longitudinal footprint while preserving full maintenance access. At 720 × 763 × 1475 mm, the unit occupies less than 0.55 m² of floor area—comparable to a standard office desk. This dimensional economy makes the ZW-6/7 ideal for installations in crowded utility rooms, containerized systems, mobile nitrogen supply trailers, and retrofit applications where existing machinery rooms lack space for larger equipment. The 0.80-tonne weight permits positioning by standard pallet jack or manual hydraulic lift, eliminating the need for overhead cranes or forklift equipment.

2. Fortschrittliches ölfreies PTFE-Dichtungssystem

The ZW-6/7 employs a selbstschmierende Kolbenring- und Führungsbandbaugruppe manufactured from high-density PTFE composites reinforced with glass fiber and bronze micro-particles. This material matrix achieves a dynamic coefficient of friction below 0.08 without any hydrocarbon lubricant, delivering Ölgehalt gemäß ISO 8573-1 Klasse 0 certification directly at the compressor discharge. For process industries where nitrogen purity is non-negotiable—such as pharmaceutical sterile manufacturing, electronics wafer fabrication, and food-grade packaging—this native oil-free performance eliminates the capital expense, energy penalty, and maintenance burden of downstream coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation.

3. Two-Stage Thermodynamic Optimization for 0.70 MPa

Der two-stage, two-row compression architecture is specifically optimized for the 0.70 MPa discharge pressure target. The first-stage cylinder compresses nitrogen from suction pressure to an intermediate pressure, after which a shell-and-tube intercooler reduces the gas temperature before second-stage compression to final discharge pressure. This staged approach limits the pressure ratio per cylinder to approximately 2.6:1, maintaining discharge temperatures below 145°C and preventing thermal degradation of the PTFE sealing elements. The two-row opposed-cylinder arrangement provides inherent first-order force balance, reducing vibration transmission to the foundation by over 80% compared to single-row designs of equivalent capacity.

4. Efficient 45 kW 380V Direct Drive

The ZW-6/7 is driven by a 45 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 IE3 premium efficiency standards. The standard 380V configuration integrates directly into conventional industrial electrical panels without requiring medium-voltage infrastructure, specialized switchgear, or step-down transformers. This electrical simplicity is particularly advantageous for small and medium enterprises upgrading from bottled nitrogen or membrane generators to on-site compression, as it minimizes electrical installation costs and commissioning complexity. The motor is direct-coupled to the crankshaft via a flexible disc coupling, eliminating belt maintenance and alignment issues.

Anwendungsszenarien

Small-Scale VPSA Nitrogen Booster Stations

For compact VPSA nitrogen generators producing 500–1,500 Nm³/h of 99.5–99.9% purity nitrogen at near-atmospheric pressure, the ZW-6/7 serves as the ideal booster companion. Its 6 m³/min capacity aligns with the output of small to medium VPSA units, while the 0.70 MPa discharge pressure provides sufficient head for distribution to multiple point-of-use stations within a facility. The ZW-6/7 nitrogen booster can be skid-mounted alongside the VPSA generator, creating a fully integrated on-site nitrogen supply system with a combined footprint under 15 m². The oil-free compression path is essential because any hydrocarbon contamination would irreversibly poison the carbon molecular sieve adsorbent, degrading separation efficiency and necessitating costly adsorbent replacement.

Pharmaceutical Process Inerting & Sterile Manufacturing

Pharmaceutical manufacturing facilities require nitrogen for reactor inerting, sterile powder conveying, vial headspace purging, and lyophilization chamber atmosphere control. The ZW-6/7’s 0.70 MPa discharge pressure is well-suited for feeding medium-pressure nitrogen headers serving multiple process skids, while its oil-free certification ensures compliance with FDA 21 CFR 211 (Current Good Manufacturing Practice) and EU GMP Annex 1 (Manufacture of Sterile Medicinal Products). The compact dimensions allow installation within existing pharmaceutical utility corridors without disrupting cleanroom layouts or requiring structural modifications.

Electronics Assembly & Semiconductor Support

In electronics manufacturing, nitrogen is deployed for reflow soldering atmosphere control, wave soldering inerting, dry cabinet storage, and component tape-and-reel packaging. The ZW-6/7’s 6 m³/min capacity can simultaneously supply multiple soldering lines and storage cabinets within a medium-sized electronics assembly facility. The oil-free design is absolutely critical in this sector because even sub-ppm oil contamination can cause solder joint defects, conformal coating delamination, and contamination of optical sensors or camera modules. The 0.70 MPa pressure provides adequate head for nitrogen distribution through standard polyethylene or copper piping networks spanning up to 500 meters.

Precision Chemical Synthesis & Catalyst Protection

Specialty chemical manufacturers and catalyst producers utilize nitrogen for reactor blanketing, catalyst bed preservation, solvent degassing, and product transfer under inert atmosphere. The ZW-6/7’s 0.70 MPa discharge pressure is sufficient for pressurized transfer of sensitive chemicals between process vessels and for maintaining positive pressure in catalyst storage silos. The oil-free compression ensures that no hydrocarbon contaminants are introduced into the process stream, which is particularly important for catalyst manufacturing where trace oil can poison active sites and reduce catalytic efficiency by 15–30%.

Material & Konstruktion

The ZW-6/7 is fabricated from materials meticulously selected for nitrogen compatibility, corrosion resistance, and compact structural integrity:

All pressure-bearing components are designed and manufactured in accordance with ASME BPVC Abschnitt VIII Division 1 or Chinese GB 150 standards. Weld joints undergo 100% radiographic inspection (RT), and each pressure vessel is hydrostatically tested at 1.5× MAWP for a minimum 30-minute hold period. The compact intercooler is specifically engineered for the ZW-6/7’s flow rate and pressure ratio, with tube-side velocities optimized for heat transfer efficiency without excessive pressure drop.

Installations- und Wartungsrichtlinien

Fundament- und Raumanforderungen

The ZW-6/7 weighs just 0.80 tonnes and features a remarkably low center of gravity due to its vertical design. A Stahlbetonplatte von 1,5–2,0 Tonnen is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 10–15 Hz). The two-row opposed-cylinder design inherently cancels first-order inertial forces, minimizing vibration transmission to adjacent sensitive equipment such as analytical balances or optical instruments. Required clearances: 0.6 m on the non-drive side for valve access, 0.5 m on the drive side for motor maintenance, and 1.0 m overhead for lifting the motor or compressor head.

Kühlwasserspezifikationen

Der Kühlwasserbedarf beträgt ungefähr 8 m³/h at an inlet temperature not exceeding 32°C. The compact intercooler and cylinder jackets share a common cooling water circuit. Acceptable water quality: pH 6.5–8.5, total hardness < 250 mg/L as CaCO₃, chloride < 50 mg/L, suspended solids < 20 mg/L. For installations without municipal water supply, a small closed-loop cooling system with a 0.5 m³ buffer tank and compact air-blast cooler is sufficient.

Wartungsplan

The oil-free architecture of the ZW-6/7 eliminates the entire category of lubricant-related maintenance tasks. There are no oil changes to schedule, no oil analysis laboratory contracts to maintain, no filter elements to stock, and no oil separator cartridges to monitor. The sole recurring consumables are the PTFE-Kolbenringe und -Zündbänder, which typically achieve 4,000–6,000 hours of service life under clean nitrogen conditions. For a facility operating 6,000 hours per year, this translates to a single scheduled maintenance event annually.

Konformitäts- und Sicherheitszertifizierungen

The ZW-6/7 nitrogen compressor meets or exceeds the following international standards and regulatory frameworks:

Leistungs- und Effizienzanalyse

The ZW-6/7 achieves a spezifischer Stromverbrauch von ca. 7,50 kW pro m³/min of nitrogen delivered at 0.70 MPa discharge pressure. While this specific power is higher than our larger LW-series models due to the reduced scale efficiency inherent in smaller compressors, it remains competitive within the sub-10 m³/min oil-free piston segment. For comparison, oil-lubricated screw compressors in this capacity range typically consume 8.0–9.0 kW/m³/min, and diaphragm compressors (frequently specified for oil-free applications) can exceed 11 kW/m³/min.

Over a 6,000-hour annual operating schedule, the ZW-6/7’s efficiency advantage versus less efficient alternatives yields approximately 18,000–36,000 kWh of energy savings per year. At $0.08/kWh, this represents $1,440–$2,880 in annual electricity cost reduction. However, the dominant economic justification for ZW-6/7 selection in most applications is the elimination of oil-related consumables and downstream purification infrastructure und nicht nur geringfügige Energieeinsparungen.

Der Gesamtbetriebskosten für die Stickstoffkompression in small to medium applications is driven primarily by maintenance labor, consumables, and capital depreciation rather than energy. The ZW-6/7’s oil-free design eliminates oil changes ($300–600/year), filter replacements ($150–300/year), separator cartridge changes ($400–800/year), and oil analysis ($100–200/year), delivering total consumable savings of $950–$1,900 annually compared to lubricated alternatives. Additionally, the absence of downstream oil-removal equipment (coalescing filters, activated carbon adsorbers, oil monitors) eliminates capital costs of $8,000–$15,000 and associated energy penalties of 3–5% of compressor power.

Anpassungs- und OEM-Fähigkeiten

We offer extensive customization options to adapt the ZW-6/7 to specific installation constraints, process requirements, and end-user preferences:

• Compact Skid Packages: Pre-assembled compressor, motor, intercooler, and control panel on a structural steel skid with forklift pockets. Reduces field installation to electrical connection and cooling water hookup only—typically completed within one working day.
• Mobile Trailer Systems: The ZW-6/7 can be mounted on a road-legal trailer with an integrated diesel generator, closed-loop cooling system, and nitrogen receiver, creating a fully mobile nitrogen supply unit for construction sites, pipeline purging, and emergency response operations.
• Intelligent Control Systems: Optional Siemens LOGO! or S7-1200 PLC with 7-inch HMI touchscreen, Ethernet connectivity, SMS/email alarm notifications, and Modbus TCP/IP compatibility for SCADA integration. Automatic load/unload control optimizes energy consumption during variable demand periods.
• Akustische Gehäuse: Compact IP54-rated sound enclosure reducing noise emission from 80 dB(A) to 65 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments such as laboratories, cleanrooms, and office-adjacent utility spaces.
• OEM- und Private-Label-Programme: Custom paint colors, branded nameplates, localized documentation, and region-specific electrical certifications for gas equipment distributors and system integrators.

Kundenspezifische Konfigurationen sind erhältlich bei Mindestbestellmenge: 1 Stück. Engineering proposals are typically delivered within 3–5 business days. Standard delivery time is 10–12 weeks from order confirmation; expedited delivery within 8 weeks is available for qualifying projects.

Case Study: Pharmaceutical Sterile Manufacturing Nitrogen Upgrade

Kunde: A sterile injectable pharmaceutical manufacturer in Thailand

Herausforderung: The facility was utilizing an oil-lubricated nitrogen compressor (5-year-old European brand) for reactor inerting and vial headspace purging. During a routine FDA pre-approval inspection, oil contamination of 1.5 mg/m³ was detected in the nitrogen supply to the aseptic filling line. This finding triggered a warning letter and required immediate corrective action, including a production hold that cost approximately $250,000 in lost batches and delayed product launch.

Lösung: Wir lieferten eine ZW-6/7 oil-free nitrogen compressor as a direct replacement, mounted on a compact skid with an integrated aftercooler and Siemens LOGO! PLC control panel. The skid was designed to fit within the existing utility room (2.5 m × 1.5 m footprint) without requiring structural modifications. A 0.5 m³ nitrogen receiver was included to dampen pressure fluctuations during rapid valve cycling in the filling line.

Results After 12 Months:

• Stickstoffgehalt des Öls: Reduzierung von 1,5 mg/m³ auf <0,01 mg/m³, achieving ISO 8573-1 Class 0 and satisfying FDA requirements
• FDA inspection outcome: Zero findings related to nitrogen quality in the subsequent follow-up inspection
• Maintenance burden: Reduced by 60%—elimination of oil changes, filter replacements, and separator overhauls
• Ungeplante Ausfallzeiten: Null Ereignisse in 12 months of continuous operation
• Production hold risk: Ausgeschieden—no further nitrogen quality-related production interruptions

“The ZW-6/7 compressor solved our compliance crisis overnight. The FDA inspector specifically noted the oil-free certification in his report, and we have had zero nitrogen quality issues since installation. The compact size was a bonus—we didn’t need to expand our utility room.” — Quality Assurance Director, Pharmaceutical Manufacturer

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Bereit für ein Upgrade Ihres Stickstoffkompressionssystems?

Our application engineers are available to evaluate your nitrogen flow requirements, inlet conditions, discharge pressure targets, and integration constraints. We provide complimentary technical proposals, layout drawings, piping and instrumentation diagrams (P&IDs), and detailed total cost of ownership (TCO) analyses within 48 hours of receiving your inquiry.

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