{"id":598,"date":"2026-07-21T07:33:37","date_gmt":"2026-07-21T07:33:37","guid":{"rendered":"https:\/\/n2-compressor.com\/?post_type=product&p=598"},"modified":"2026-07-21T07:33:37","modified_gmt":"2026-07-21T07:33:37","slug":"zw-3-50-nitrogen-compressor","status":"publish","type":"product","link":"https:\/\/n2-compressor.com\/de\/produkt\/zw-3-50-nitrogen-compressor\/","title":{"rendered":"ZW-3\/50 Stickstoffkompressor | 3 m\u00b3\/min \u00f6lfreier N2-Booster f\u00fcr kritische Prozesse mit Ultrahochdruck (5,00 MPa)"},"content":{"rendered":"
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ZW-3\/50 Nitrogen Compressor \u2013 Ultra-High-Pressure Oil-Free N2 Booster for 5.00 MPa Critical Process Applications<\/p>\n

Engineered to deliver 3 m\u00b3\/min at 5.00 MPa discharge pressure, the ZW-3\/50 is a two-stage, three-row oil-free piston nitrogen compressor designed for ultra-high-pressure nitrogen injection, gas cylinder cascade filling, and critical petrochemical process applications. Zero oil contamination, reinforced high-pressure construction, and optimized for demanding continuous-duty operation at extreme pressure.<\/p>\n

Angebot anfordern<\/a>
\nN2-Kompressorserie ansehen<\/a><\/div>\n

\"ZW-3\/50<\/p>\n<\/div>\n

<\/p>\n

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Produkt\u00fcbersicht<\/h2>\n

Der ZW-3\/50 nitrogen compressor<\/strong> occupies the ultra-high-pressure segment of our oil-free piston compressor portfolio, engineered specifically for applications where nitrogen must be delivered at pressures far exceeding conventional industrial distribution limits. With a rated capacity of 3 m\u00b3\/min<\/strong> und ein au\u00dfergew\u00f6hnlicher 5.00 MPa discharge pressure<\/strong>, this unit addresses the most demanding nitrogen compression requirements in specialized industrial and research applications.<\/p>\n

What distinguishes the ZW-3\/50 from conventional alternatives is its vollst\u00e4ndig \u00f6lfreier Kompressionsweg<\/strong> combined with ultra-high-pressure capability. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials specifically formulated for extreme pressure service. At 5.00 MPa, the risk of oil contamination is dramatically magnified compared to low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for any application where nitrogen purity cannot be compromised.<\/p>\n

Der Kompressor verwendet einen zweistufig, dreireihig (\u4e8c\u5217\u4e09\u7ea7)<\/strong> configuration that is essential for managing the extreme pressure ratio required to achieve 5.00 MPa discharge pressure from typical inlet conditions. The three-row design provides superior force balance and reduced vibration compared to single-row alternatives, while the two-stage arrangement ensures that discharge temperatures remain within the safe operating limits of the PTFE sealing materials. Each stage features independent high-efficiency cooling, and the entire assembly is mounted on a reinforced structural frame designed to withstand the mechanical stresses of ultra-high-pressure operation.<\/p>\n

\"ZW-3\/50<\/p>\n<\/div>\n

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Technical Specifications \u2013 ZW-3\/50<\/h2>\n
\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
Parameter<\/th>\nWert<\/th>\nEinheit<\/th>\n<\/tr>\n<\/thead>\n
Modell<\/td>\nZW-3\/50<\/td>\n\u2013<\/td>\n<\/tr>\n
Muster<\/td>\nZweistufig, dreireihig (\u4e8c\u5217\u4e09\u7ea7)<\/td>\n\u2013<\/td>\n<\/tr>\n
Kapazit\u00e4t<\/td>\n3<\/td>\nm\u00b3\/min<\/td>\n<\/tr>\n
Entladedruck<\/td>\n5.00<\/td>\nMPa<\/td>\n<\/tr>\n
Kompressorgr\u00f6\u00dfe (L \u00d7 B \u00d7 H)<\/td>\n1920 \u00d7 1900 \u00d7 2580<\/td>\nmm<\/td>\n<\/tr>\n
Gewicht<\/td>\n3.97<\/td>\nT<\/td>\n<\/tr>\n
Leistung<\/td>\n55<\/td>\nkW<\/td>\n<\/tr>\n
Stromspannung<\/td>\n380<\/td>\nV<\/td>\n<\/tr>\n
Gasmedium<\/td>\nStickstoff (N\u2082)<\/td>\n\u2013<\/td>\n<\/tr>\n
Schmierung<\/td>\n\u00d6lfrei<\/td>\n\u2013<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

* Alle Spezifikationen beziehen sich auf Standardreferenzbedingungen (ISO 1217, Anhang C). Die tats\u00e4chliche Leistung kann je nach Standorth\u00f6he, Umgebungstemperatur und Einlassbedingungen variieren.<\/em><\/p>\n<\/div>\n

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Hauptmerkmale und technische Vorteile<\/h2>\n

1. Ultra-High-Pressure Oil-Free PTFE Sealing System<\/h3>\n

The ZW-3\/50 utilizes a proprietary selbstschmierende Kolbenring- und F\u00fchrungsbandbaugruppe<\/strong> manufactured from ultra-high-performance PTFE composites specifically engineered for extreme pressure service. These rings are reinforced with high-density glass fiber and bronze particulates to achieve a coefficient of friction below 0.05 without any external hydrocarbon lubrication. At 5.00 MPa discharge pressure, the partial pressure of oil vapor would be catastrophically high if any lubricant were present, making the oil-free design an absolute requirement. The PTFE formulation is rated for continuous operation at temperatures up to 185\u00b0C, ensuring reliable sealing integrity even under the extreme thermal stress of ultra-high-pressure compression.<\/p>\n

2. Three-Row Design for Superior Force Balance<\/h3>\n

Der zweistufig, dreireihig (\u4e8c\u5217\u4e09\u7ea7)<\/strong> architecture of the ZW-3\/50 is mechanically sophisticated, distributing the compression work across three cylinders arranged in a force-balanced configuration. This three-row design provides superior first-order and second-order force cancellation<\/strong> compared to single-row or two-row alternatives, dramatically reducing vibration transmission to the foundation. At 5.00 MPa, the peak gas forces on the pistons are substantial, and the three-row arrangement ensures that these forces are balanced both vertically and horizontally. This mechanical advantage permits installation on a lighter foundation than would be required for an equivalent single-row compressor, and it reduces the stress on surrounding structures and connected piping.<\/p>\n

3. Reinforced High-Pressure Frame Construction<\/h3>\n

Der Hauptrahmen ist gegossen aus GG30 Grauguss<\/strong> (higher grade than standard GG25) with significantly reinforced wall sections, additional ribbing, and integral cooling water passages. The high-pressure cylinder block features thicker wall castings, stress-relieving heat treatment, and precision honing<\/strong> to ensure dimensional stability under the extreme pressures of 5.00 MPa operation. All high-pressure components are subjected to 100% ultrasonic testing (UT) to detect any internal defects that could compromise pressure integrity. The crankshaft is forged from 42CrMo4 alloy steel, quenched and tempered, and dynamically balanced to ISO 1940 G1.0 standards\u2014stricter than the G2.5 standard used for lower-pressure compressors.<\/p>\n

4. Standard 380V Drive with High-Torque Motor<\/h3>\n

The ZW-3\/50 is driven by a 55 kW, 380 V, 50 Hz Drehstrom-Induktionsmotor<\/strong> with a high-torque design optimized for the starting loads of ultra-high-pressure compression. The motor conforms to IEC 60034-1 efficiency class IE3 and features a service factor of 1.15 to accommodate the peak torque demands during startup and pressure buildup. The standard 380V configuration integrates directly into existing industrial distribution panels, making the unit accessible to facilities without medium-voltage infrastructure. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied.<\/p>\n

\"ZW-3\/50<\/p>\n<\/div>\n

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Anwendungsszenarien<\/h2>\n

Ultra-High-Pressure Nitrogen Cylinder Cascade Filling<\/h3>\n

The ZW-3\/50 is ideally suited for cylinder filling stations<\/strong> where nitrogen must be compressed to pressures approaching or exceeding 20 MPa for standard industrial cylinders. While the compressor’s 5.00 MPa discharge pressure does not reach cylinder filling pressure directly, it serves as a highly efficient intermediate booster that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. By boosting nitrogen from 0.05\u20130.10 MPa to 5.00 MPa, the ZW-3\/50 reduces the work required of the final filling stage by approximately 60%, improving overall system efficiency and extending the life of the expensive high-pressure filling equipment. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users.<\/p>\n

\"ZW-3\/50<\/p>\n

Critical Petrochemical Emergency Nitrogen Injection<\/h3>\n

In petrochemical and refinery operations, the ZW-3\/50 provides ultra-high-pressure nitrogen for emergency injection into high-pressure reactors, catalyst bed preservation, and rapid inerting of process vessels<\/strong>. The 5.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 4.0 MPa, maintaining positive inert gas flow even during upset conditions. The ZW-3\/50 ultra-high-pressure nitrogen compressor<\/a> is often installed as a dedicated emergency backup unit, ready to activate automatically when process safety systems detect hazardous conditions. The oil-free certification ensures that emergency nitrogen does not introduce contaminants that could poison catalysts or compromise product quality during recovery operations.<\/p>\n

Extraktion und Verarbeitung \u00fcberkritischer Fluide<\/h3>\n

Supercritical fluid extraction (SFE) processes using nitrogen require pressures in the range of 3.0\u20137.0 MPa to achieve the supercritical state. The ZW-3\/50’s 5.00 MPa discharge pressure is ideally positioned for supercritical nitrogen extraction of pharmaceuticals, natural products, and specialty chemicals<\/strong>. The oil-free design is absolutely critical in SFE applications because any hydrocarbon contamination would co-extract with the target compounds, contaminating the final product and potentially creating toxic impurities in pharmaceutical extracts. The 3 m\u00b3\/min capacity is well-matched to pilot-scale and small production-scale SFE systems.<\/p>\n

\"ZW-3\/50<\/p>\n

High-Pressure Pipeline Pressure Testing & Purging<\/h3>\n

Natural gas pipelines, hydrogen pipelines, and high-pressure process piping require nitrogen pressure testing and purging<\/strong> before commissioning and after maintenance. The ZW-3\/50’s 5.00 MPa discharge pressure is sufficient for hydrostatic testing equivalent to pipeline operating pressures up to 3.5 MPa (per ASME B31.8, testing at 1.25\u00d7 MAOP) and for pneumatic testing at pressures up to 4.0 MPa. Nitrogen is preferred over compressed air for pipeline testing because it eliminates the explosion risk associated with oxygen in the presence of hydrocarbon residues. The oil-free design ensures that test nitrogen does not leave hydrocarbon contaminants in the pipeline that could affect subsequent product quality.<\/p>\n<\/div>\n

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Material & Konstruktion<\/h2>\n

The ZW-3\/50 is constructed from premium materials specifically selected for ultra-high-pressure nitrogen service, thermal resistance, and extreme mechanical integrity:<\/p>\n

\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
Komponente<\/th>\nMaterial<\/th>\nSpezifikation<\/th>\n<\/tr>\n<\/thead>\n
Zylinderblock (LP)<\/td>\nGrauguss<\/td>\nGG30 \/ HT300, standard wall thickness<\/td>\n<\/tr>\n
Zylinderblock (PS)<\/td>\nGrauguss<\/td>\nGG30 \/ HT300, heavy wall + reinforced ribbing<\/td>\n<\/tr>\n
Kurbelwelle<\/td>\nGeschmiedeter legierter Stahl<\/td>\n42CrMo4, Q&T, ISO 1940 G1.0 balanced<\/td>\n<\/tr>\n
Kolbenringe<\/td>\nPTFE-Glas-Bronze-Verbundwerkstoff<\/td>\nF\u00fcr Ultrahochdruck geeignet, selbstschmierend, max. 185 \u00b0C<\/td>\n<\/tr>\n
Reiterb\u00e4nder<\/td>\nPTFE-Verbundwerkstoff<\/td>\nKolbenf\u00fchrung, Verschlei\u00dfschutz, Verschlei\u00dfrate <0,03 mm\/1000 h<\/td>\n<\/tr>\n
Ventilplatten<\/td>\nEdelstahl<\/td>\nSS316, ultra-high-pressure concentric ring design<\/td>\n<\/tr>\n
Pleuelstangen<\/td>\nGeschmiedeter Stahl mit Gleitlagern<\/td>\nPr\u00e4zisionsgefertigtes, \u00f6lgeschmiertes Pleuelauge<\/td>\n<\/tr>\n
Ladeluftk\u00fchler<\/td>\nGeh\u00e4use aus Kohlenstoffstahl \/ Rohre aus Edelstahl 316<\/td>\nASME VIII Div.1, 1,5-fache Druckpr\u00fcfung, 30 min Haltezeit<\/td>\n<\/tr>\n
Ladeluftk\u00fchler<\/td>\nGeh\u00e4use aus Kohlenstoffstahl \/ Rohre aus Edelstahl 316<\/td>\nHochdruck-Rippenrohr, 32 \u00b0C K\u00fchlwasser<\/td>\n<\/tr>\n
Hochdruckleitungen<\/td>\nNahtloser Edelstahl<\/td>\nEdelstahl 316, ANSI-Klasse 900 Flansche<\/td>\n<\/tr>\n
Grundrahmen<\/td>\nSchwerer Baustahl<\/td>\nWelded, reinforced, vibration-damped mounting<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Alle drucktragenden Bauteile werden in strikter \u00dcbereinstimmung mit den geltenden Bestimmungen konstruiert und gefertigt. ASME BPVC Abschnitt VIII Division 1<\/strong> or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2, and 100% ultrasonic testing (UT) per ASME Section V, Article 4. Each completed pressure vessel is subjected to a hydrostatic pressure test at 1.5 times the MAWP for a minimum hold period of 30 minutes. High-pressure piping systems are fabricated from seamless SS316 with ANSI Class 900 flanged connections to ensure leak-tight integrity at 5.00 MPa operating pressure.<\/p>\n

\"ZW-3\/50<\/p>\n<\/div>\n

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Installations- und Wartungsrichtlinien<\/h2>\n

Fundament- und Strukturanforderungen<\/h3>\n

The ZW-3\/50 has a dry weight of 3.97 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the three-row force-balanced design, the extreme gas forces at 5.00 MPa require a Stahlbeton-Tr\u00e4gheitsblock von 6\u20138 Tonnen<\/strong> mounted on heavy-duty elastomeric vibration isolators (natural frequency 6\u20138 Hz). The foundation must be designed to withstand not only the static weight but also the dynamic forces generated during pressure pulsation. Minimum clearance requirements: 1.2 m on the non-drive side for valve access, 1.0 m on the drive side for motor maintenance, and 1.8 m overhead for crane access. The high-pressure discharge piping must be independently supported with spring hangers or rigid anchors to prevent vibration transmission and fatigue failure.<\/p>\n

Auslegung des K\u00fchlwassersystems<\/h3>\n

Der K\u00fchlwasserbedarf betr\u00e4gt ungef\u00e4hr 14 m\u00b3\/h<\/strong> at an inlet temperature not exceeding 32\u00b0C. The water distribution circuit supplies the cylinder jackets and intercooler in parallel, with the intercooler receiving priority flow due to the extreme heat of compression at 5.00 MPa. Water quality specifications: pH 6.5\u20138.5, total dissolved solids < 500 mg\/L, chloride content < 50 mg\/L (to prevent SS316 tube corrosion), suspended solids < 20 mg\/L, and total hardness < 250 mg\/L as CaCO\u2083. A closed-loop cooling tower with side-stream filtration and chemical treatment is strongly recommended for all installations to prevent scale formation and corrosion in the high-efficiency coolers.<\/p>\n

Wartungsplan<\/h3>\n
\n\n\n\n\n\n\n\n\n\n
Intervall<\/th>\nServiceartikel<\/th>\nHandlungsbedarf erforderlich<\/th>\n<\/tr>\n<\/thead>\n
T\u00e4glich<\/td>\nBetriebspr\u00fcfung<\/td>\nCheck vibration, abnormal noise, cooling water flow, discharge pressure, temperature, safety valve status<\/td>\n<\/tr>\n
200 hours<\/td>\nVentilplattenpr\u00fcfung<\/td>\nRemove and inspect suction\/discharge valves for carbon deposits, spring fatigue, cracking, seat wear<\/td>\n<\/tr>\n
800 hours<\/td>\nBeurteilung des Kolbenringverschlei\u00dfes<\/td>\nMeasure ring groove clearance; replace rings if clearance exceeds 0.18 mm<\/td>\n<\/tr>\n
2.500 Stunden<\/td>\nZwischen\u00fcberholung<\/td>\nReplace all piston rings, rider bands, and valve plate assemblies; inspect high-pressure cylinder bore<\/td>\n<\/tr>\n
5.000 Stunden<\/td>\nGeneral\u00fcberholung<\/td>\nInspect crankshaft journals, measure main bearing clearances, replace bearings if >0.06 mm; inspect frame<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

The oil-free design of the ZW-3\/50 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. However, the extreme pressure conditions mean that the PTFE-Kolbenringe und -Z\u00fcndb\u00e4nder<\/strong> experience higher wear rates than in low-pressure service, with typical replacement intervals of 2,500\u20134,000 hours. The high-pressure valve plates require particularly close monitoring due to the increased mechanical and thermal stress at 5.00 MPa. Despite these considerations, the overall maintenance burden remains significantly lower than oil-lubricated systems of equivalent pressure capability.<\/p>\n

\"ZW-3\/50<\/p>\n<\/div>\n

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Konformit\u00e4ts- und Sicherheitszertifizierungen<\/h2>\n

The ZW-3\/50 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:<\/p>\n

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Druckger\u00e4te<\/strong>
\nASME BPVC Abschnitt VIII Div.1, GB 150-2011, PED 2014\/68\/EU Modul A<\/span><\/div>\n
Elektrische und Maschinensicherheit<\/strong>
\nIEC 60034-1 (IE3-Effizienz), IEC 60204-1, ISO 12100 Maschinensicherheit<\/span><\/div>\n
\u00d6lfrei-Zertifizierung<\/strong>
\nISO 8573-1 Klasse 0 (\u00d6lgehalt), unabh\u00e4ngig gepr\u00fcft vom T\u00dcV Rheinland<\/span><\/div>\n
Qualit\u00e4t & Umwelt<\/strong>
\nISO 9001:2015, ISO 14001:2015<\/span><\/div>\n<\/div>\n
\u26a0\ufe0f Kritischer Sicherheitshinweis \u2013 Betrieb unter Ultrahochdruck<\/strong><\/p>\n

Nitrogen is classified as a simple asphyxiant gas. At 5.00 MPa discharge pressure, the risk of rapid gas release and oxygen displacement is EXTREMELY elevated. All ZW-3\/50 installations must incorporate: (1) Continuous oxygen deficiency monitoring in the compressor room and all adjacent areas; (2) High-pressure discharge piping equipped with pressure relief valves rated at 110% of MAWP and rupture discs as secondary protection; (3) Automatic emergency isolation valves on the suction and discharge lines; (4) Ventilation systems engineered to maintain ambient oxygen above 19.5% per OSHA 29 CFR 1910.146; (5) Emergency shutdown interlocks activating at 19.5% O\u2082 (alarm) and triggering hard isolation at 18.0% O\u2082; (6) Personnel trained in ultra-high-pressure gas safety protocols before any operation or maintenance. NEVER attempt to disassemble high-pressure components without complete depressurization and lockout\/tagout procedures.<\/p>\n<\/div>\n

\"ZW-3\/50<\/p>\n<\/div>\n

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Leistungs- und Effizienzanalyse<\/h2>\n

The ZW-3\/50 achieves a specific power consumption of approximately 18.33 kW per m\u00b3\/min<\/strong> of nitrogen delivered at 5.00 MPa discharge pressure. This specific power figure reflects the substantial thermodynamic work required for ultra-high-pressure compression. Within the ultra-high-pressure oil-free compressor segment (discharge pressure >4.00 MPa), this efficiency is competitive and significantly superior to diaphragm compressors, which are the primary alternative for oil-free service at these pressures. For comparison, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 20\u201325 kW\/m\u00b3\/min, while diaphragm compressors may exceed 30 kW\/m\u00b3\/min.<\/p>\n

Over an 8,000-hour annual operating cycle, the ZW-3\/50’s efficiency advantage versus less efficient alternatives yields approximately 80,000\u2013160,000 kWh of annual energy savings<\/strong>. At $0.08\/kWh, this represents $6,400\u2013$12,800 in direct electricity cost reduction per year. However, the primary economic driver for ZW-3\/50 selection is typically the Eliminierung von \u00f6lbezogenen Verbrauchsmaterialien und Vermeidung nachgelagerter \u00d6lentfernungsanlagen<\/strong> that would be mandatory with lubricated alternatives. At 5.00 MPa, the concentration of oil contamination would be approximately 15\u201320 times higher than at 0.30 MPa, making downstream oil removal prohibitively expensive and technically challenging.<\/p>\n

Der Gesamtbetriebskosten f\u00fcr die Ultrahochdruck-Stickstoffkompression<\/a> is dominated by equipment reliability and maintenance labor rather than marginal energy savings. The ZW-3\/50’s oil-free design eliminates the chronic maintenance issues associated with oil-lubricated high-pressure compressors, including oil degradation at high temperature, oil carryover into downstream equipment, and frequent oil filter clogging under high differential pressure.<\/p>\n<\/div>\n

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Anpassungs- und OEM-F\u00e4higkeiten<\/h2>\n

We offer comprehensive customization options to adapt the ZW-3\/50 to specific site conditions, safety requirements, and integration needs:<\/p>\n