Descripción
Compresor de nitrógeno 3ZW-6/30: compresor de nitrógeno de tres etapas sin aceite para aplicaciones de procesos de alta presión de 3,00 MPa.
Diseñado para ofrecer 6 m³/min a una presión de descarga de 3,00 MPa, el 3ZW-6/30 es un compresor de nitrógeno de pistón de tres etapas y tres filas, libre de aceite, ideal para la inyección de nitrógeno a ultra alta presión, estaciones de llenado de cilindros de gas y procesos exigentes de síntesis química. Ofrece cero contaminación por aceite, una robusta arquitectura multietapa y está optimizado para un funcionamiento continuo a presiones extremas.
Descripción general del producto
El 3ZW-6/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor technology, engineered specifically for applications that demand both substantial flow capacity and ultra-high discharge pressure. With a rated capacity of 6 m³/min y una excepcional Presión de descarga de 3,00 MPa, this unit occupies the high-pressure segment of our industrial nitrogen compressor portfolio, serving the most demanding process applications in the chemical, petrochemical, and gas distribution industries.
The “3ZW” designation signifies the three-stage, three-row (三列三级) architecture that is fundamental to achieving the 3.00 MPa discharge pressure while maintaining thermal stability and mechanical reliability. Each of the three compression stages operates at a moderate pressure ratio, with dedicated intercoolers between stages removing the heat of compression. This multi-staged approach is essential because the overall pressure ratio from atmospheric inlet to 3.00 MPa exceeds the safe operating limits of single-stage or two-stage designs, both in terms of discharge temperature and mechanical stress on the pistons and crankshaft.
What distinguishes the 3ZW-6/30 from conventional alternatives is its vía de compresión totalmente libre de aceite. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is exponentially higher than at low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for any application requiring high-purity nitrogen. The unit achieves Certificación ISO 8573-1 Clase 0 natively, without downstream oil-filtration equipment.
Technical Specifications – 3ZW-6/30
| Parámetro | Valor | Unidad |
|---|---|---|
| Modelo | 3ZW-6/30 | – |
| Patrón | Three-stage, Three-row (三列三级) | – |
| Capacidad | 6 | m³/min |
| Presión de descarga | 3.00 | MPa |
| Dimensiones del compresor (largo × ancho × alto) | 1845 × 1660 × 2360 | mm |
| Peso | 3.00 | t |
| Fuerza | 75 | kW |
| Voltaje | 380 | V |
| Medio gaseoso | Nitrógeno (N₂) | – |
| Lubricación | Sin aceite | – |
* Todas las especificaciones se basan en condiciones de referencia estándar (ISO 1217, Anexo C). El rendimiento real puede variar según la altitud del lugar, la temperatura ambiente y las condiciones de entrada.
Características principales y ventajas de ingeniería
1. Three-Stage Compression for Ultra-High Pressure
El three-stage, three-row architecture of the 3ZW-6/30 is the engineering foundation that makes 3.00 MPa discharge pressure achievable with oil-free piston technology. The overall pressure ratio of approximately 30:1 to 60:1 (from atmospheric inlet) is divided across three compression cylinders, with each stage operating at a pressure ratio of approximately 3:1 to 4:1. This staged approach is thermodynamically essential because single-stage compression to 3.00 MPa would produce discharge temperatures exceeding 300°C, far beyond the safe operating limit of PTFE sealing materials. Between each stage, a dedicated high-efficiency shell-and-tube intercooler removes the heat of compression, maintaining discharge temperatures below 155°C at all stages. This thermal management preserves PTFE ring integrity and extends valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios.
2. Advanced High-Pressure Oil-Free PTFE Sealing System
The 3ZW-6/30 employs a proprietary Conjunto de anillo de pistón autolubricante y banda de apoyo manufactured from ultra-high-performance PTFE composites specifically formulated for 3.00 MPa service. These rings are reinforced with glass fiber, bronze particulates, and molybdenum disulfide to achieve a coefficient of friction below 0.05 without any external hydrocarbon lubrication. At 3.00 MPa discharge pressure, the partial pressure of oil vapor would be approximately 10 times higher than at 0.30 MPa, making oil contamination exponentially more severe and more difficult to remove downstream. The 3ZW-6/30’s native oil-free design achieves Certificación ISO 8573-1 Clase 0 without any downstream filtration, coalescing, or adsorption equipment. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, with a safety margin that accommodates transient temperature excursions during startup and load changes.
3. Three-Row Opposed-Cylinder Force Balance
El marco principal está fundido a partir de Hierro fundido gris GG25 with reinforced wall sections and integral cooling water passages. The three-row opposed-cylinder arrangement provides superior force balance compared to single-row or two-row designs, with first-order and second-order inertial forces largely self-canceling. This mechanical advantage is particularly critical for high-pressure compressors where the peak gas forces on the pistons are substantially higher than in low-pressure applications. The three-row configuration reduces the unbalanced forces transmitted to the foundation by over 85% compared to single-row designs, permitting installation on a lighter reinforced concrete inertia block (minimum 5 tonnes) and reducing the risk of vibration-induced fatigue in connected piping systems. The compact dimensions—1845 × 1660 × 2360 mm—are remarkable for a three-stage compressor of this pressure class, achieved through a vertically stacked cylinder arrangement that minimizes the machine’s footprint.
4. Accionamiento de motor industrial estándar de 380 V
The 3ZW-6/30 is driven by a Motor de inducción trifásico de 75 kW, 380 V, 50 Hz 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 is particularly valuable for the 3ZW-6/30 because its moderate power requirement (75 kW) does not justify the complexity and cost of medium-voltage infrastructure. The motor is directly coupled to the crankshaft through a flexible disc coupling, eliminating the maintenance burden and efficiency losses associated with belt or gearbox drives.
Escenarios de aplicación
Ultra-High-Pressure Nitrogen Cylinder Filling
The 3ZW-6/30 is the ideal primary booster for nitrogen cylinder filling stations serving industrial, medical, and specialty gas markets. While the compressor’s 3.00 MPa discharge pressure does not reach the 15–20 MPa required for direct cylinder filling, it serves as a highly efficient intermediate stage that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. In a typical filling station configuration, the 3ZW-6/30 boosts nitrogen from 0.05–0.10 MPa to 3.00 MPa, after which a compact high-pressure diaphragm or piston compressor completes the filling to 20 MPa. This staged approach improves overall system efficiency by 25–35% compared to single-stage high-pressure compression from atmospheric inlet. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the filled cylinders and delivered to end-users, potentially compromising their processes and exposing the filling station to liability.
Chemical Synthesis & High-Pressure Reactor Inerting
In chemical process plants, the 3ZW-6/30 nitrogen compressor provides ultra-high-pressure nitrogen for high-pressure reactor inerting, catalyst bed preservation, and emergency depressurization of process vessels. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into reactors operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during all phases of operation. The three-stage compression ensures that the nitrogen remains thermally stable and free of oil contamination, which is critical in chemical synthesis where even trace contaminants can poison catalysts, initiate unwanted side reactions, or compromise product purity. The 6 m³/min capacity can serve multiple high-pressure reactors simultaneously through a centralized nitrogen header.
Gas Liquefaction & Cryogenic Storage Pressure Maintenance
In nitrogen liquefaction plants and cryogenic storage facilities, the 3ZW-6/30 serves as a high-pressure booster that compresses nitrogen vapor from storage tanks or recondensers to the pressure required for distribution or further processing. The 3.00 MPa discharge pressure is adequate for driving nitrogen through heat exchangers, recondensers, and distribution networks in small to medium liquefaction plants. The oil-free design is essential because any oil contamination in the high-pressure nitrogen would be carried into the cryogenic system, where it would freeze and block heat exchanger passages, causing operational failures and costly maintenance. The three-stage compression with intercooling ensures that the nitrogen remains at manageable temperatures throughout the compression process, preventing thermal damage to downstream cryogenic equipment.
Oil & Gas Well Nitrogen Injection
In oil and gas production operations, high-pressure nitrogen is injected into wells for enhanced oil recovery (EOR), well stimulation, and gas lift operations. The 3ZW-6/30’s 3.00 MPa discharge pressure is sufficient for many shallow to medium-depth well applications, where nitrogen is used to displace oil, reduce reservoir pressure, or lift production fluids to the surface. The oil-free design prevents hydrocarbon contamination of the reservoir, which could alter formation permeability and reduce oil recovery efficiency. The 6 m³/min capacity can support continuous nitrogen injection for extended well stimulation campaigns or intermittent gas lift operations for multiple wells.
Materiales y construcción
The 3ZW-6/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, thermal resistance, and extended operational life:
| Componente | Material | Especificación |
|---|---|---|
| Cylinder Block (1st Stage) | Hierro fundido gris | GG25 / HT250, espesor de pared estándar |
| Cylinder Block (2nd Stage) | Hierro fundido gris | GG25 / HT250, pared reforzada + nervaduras |
| Cylinder Block (3rd Stage) | Hierro fundido gris | GG25 / HT250, heavy-duty reinforced wall |
| Cigüeñal | Acero aleado forjado | 42CrMo4, Q&T, ISO 1940 G2.5, equilibrado dinámicamente |
| Anillos de pistón | Compuesto de PTFE-vidrio-bronce-MoS₂ | Soporta presiones ultra altas, es autolubricante y alcanza una temperatura máxima de 185 °C. |
| Bandas de jinete | Compuesto de PTFE | Guía del pistón, antidesgaste, tasa de desgaste <0,04 mm/1000 h |
| Placas de válvulas | Acero inoxidable | Diseño de anillos concéntricos de alta presión, fabricado en acero inoxidable SS316. |
| Intercoolers (×2) | Carcasa de acero al carbono / Tubos de acero inoxidable SS316 | ASME VIII Div.1, prueba hidrostática 1,5×, retención de 30 min |
| posenfriador | Carcasa de acero al carbono / Tubos de acero inoxidable SS316 | Tubo aleteado de alta presión, agua de refrigeración a 32 °C |
| Tuberías de alta presión | Acero inoxidable sin costuras | Bridas de acero inoxidable SS316, clase ANSI 900 |
Todos los componentes sometidos a presión están diseñados y fabricados en estricta conformidad con ASME BPVC Sección VIII División 1 o las normas chinas GB 150. Cada junta soldada se somete a una inspección radiográfica (RT) 100% según la Sección V, Artículo 2 de ASME, y cada recipiente a presión terminado se somete a una prueba de presión hidrostática a 1,5 veces la presión máxima de trabajo admisible (MAWP) durante un período mínimo de 30 minutos. Los sistemas de tuberías de alta presión se fabrican con acero inoxidable SS316 sin costura con conexiones bridadas ANSI Clase 900 para garantizar la estanqueidad a una presión de funcionamiento de 3,00 MPa.
Guía de instalación y mantenimiento
Requisitos estructurales y de cimentación
The 3ZW-6/30 has a dry weight of 3.00 tonnes and a center of gravity approximately 800 mm above the baseplate. Thanks to the three-row opposed-cylinder design, unbalanced forces are minimal despite the ultra-high-pressure operation, permitting installation on a Bloque de inercia de hormigón armado de 5 a 6 toneladas. The block should be mounted on elastomeric vibration isolators (natural frequency 7–10 Hz). 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 1.5 m overhead for crane access. Special attention must be paid to the high-pressure discharge piping, which must be properly supported with spring hangers and anchored to prevent vibration-induced fatigue at 3.00 MPa. All high-pressure connections must be verified with ultrasonic testing after installation.
Diseño del sistema de agua de refrigeración
La demanda de agua de refrigeración es aproximadamente 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and two intercoolers in parallel branches. Given the three-stage compression and high pressure ratio, the intercoolers are absolutely critical for thermal management and must receive adequate cooling water flow at all times. 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 and chemical treatment is strongly recommended for all installations to ensure consistent water quality and prevent scale formation in the intercoolers.
Programa de mantenimiento preventivo
| Intervalo | Artículo de servicio | Acción requerida |
|---|---|---|
| A diario | Inspección operativa | Check vibration, abnormal noise, cooling water flow, discharge pressure/temperature at all stages |
| 250 horas | Inspección de la placa de válvulas (todas las etapas) | Retire e inspeccione todas las válvulas de succión/descarga para detectar depósitos de carbono, fatiga de los resortes y grietas. |
| 1.000 horas | Evaluación del desgaste de los anillos del pistón (todas las etapas) | Measure groove clearance at all stages; replace rings if clearance exceeds 0.18 mm |
| 2,500 hours | Revisión intermedia | Reemplace todos los anillos de pistón, las bandas de retención y los conjuntos de placas de válvulas en las tres etapas. |
| 5,000 hours | Revisión general | Inspect crankshaft journals, measure all bearing clearances, replace bearings if >0.06 mm |
The oil-free design of the 3ZW-6/30 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 Anillos de pistón y bandas de retención de PTFE, which typically achieve 2,500–4,000 hours of service life under clean nitrogen conditions at ultra-high pressure. The high-pressure valve plates (particularly on the third stage) may require more frequent inspection than low-pressure equivalents due to the increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems of equivalent pressure capability.
Certificaciones de cumplimiento y seguridad
The 3ZW-6/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Sección VIII Div.1, GB 150-2011, PED 2014/68/EU Módulo A
IEC 60034-1 (eficiencia IE3), IEC 60204-1, ISO 12100 seguridad de maquinaria
ISO 8573-1 Clase 0 (Contenido de aceite), probado independientemente por TÜV Rheinland.
ISO 9001:2015 (Gestión de la calidad), ISO 14001:2015 (Gestión ambiental)
Nitrogen is classified as a simple asphyxiant gas. At 3.00 MPa discharge pressure, the risk of rapid gas release and oxygen displacement is extremely elevated. All 3ZW-6/30 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and all adjacent areas. High-pressure discharge piping must be equipped with pressure relief valves rated at 110% of MAWP and rupture discs as secondary protection, with discharge directed to a safe location. All high-pressure piping must be designed, fabricated, and inspected in accordance with ASME B31.3 (Process Piping). Ventilation systems must maintain ambient oxygen above 19.5% per OSHA 29 CFR 1910.146. Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger automatic isolation at 18.0% O₂ (hard shutdown). Personnel must be trained in ultra-high-pressure gas safety protocols and wear appropriate PPE before operating or maintaining this equipment. No personnel shall be present in the compressor room during pressure testing or initial startup.
Análisis de rendimiento y eficiencia
The 3ZW-6/30 achieves a consumo de potencia específico de aproximadamente 12,50 kW por m³/min of nitrogen delivered at 3.00 MPa discharge pressure from atmospheric inlet. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the ultra-high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is competitive and significantly superior to diaphragm compressors, which are the primary alternative for oil-free ultra-high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 13.0–15.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the 3ZW-6/30’s efficiency advantage versus less efficient alternatives yields approximately 72,000–144,000 kWh of annual energy savings. At $0.08/kWh, this represents $5,760–$11,520 in direct electricity cost reduction per year. However, the primary economic justification for the 3ZW-6/30 is typically the eliminación de consumibles relacionados con el petróleo y evitación de equipos de eliminación de petróleo posteriores that would be mandatory with lubricated alternatives at this pressure level. The Coste total de propiedad para la compresión de nitrógeno a ultra alta presión. Se reduce en un estimado de 30–45% durante una vida útil operativa de 10 años cuando se compara el funcionamiento sin aceite con sistemas lubricados con purificación completa aguas abajo.
The absence of oil in the compression path is particularly valuable at ultra-high pressure because oil contamination becomes exponentially more concentrated and more difficult to remove as pressure increases. At 3.00 MPa, the partial pressure of oil vapor would be approximately 15 times higher than at 0.30 MPa, making downstream oil-filtration systems virtually ineffective and prohibitively expensive. The 3ZW-6/30’s native oil-free design eliminates this challenge entirely, ensuring that nitrogen purity is maintained regardless of operating pressure.
Capacidades de personalización y fabricación de equipos originales (OEM)
We offer comprehensive customization options to adapt the 3ZW-6/30 to specific site conditions, integration requirements, and end-user specifications:
- Paquetes llave en mano montados sobre patines: Pre-assembled compressor, motor, three intercoolers, aftercooler, high-pressure discharge piping, instrumentation, and control panel on a structural steel skid with integrated lifting lugs and anchor bolt templates. Factory pre-testing of all systems reduces commissioning time by 70%.
- Configuraciones de áreas peligrosas: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection, automatic ventilation interlocks, and explosion-proof instrumentation.
- Control avanzado de procesos: Optional Siemens S7-1200 or Allen-Bradley CompactLogix PLC with 10-inch HMI touchscreen, remote monitoring via Modbus TCP/IP or OPC-UA, and seamless DCS/SCADA integration. Automatic stage-by-stage pressure monitoring and alarm systems. High-pressure safety interlocks including automatic unload on overpressure and emergency isolation valves on all stages.
- Protección ambiental: Recubrimientos de grado marino C5-M para instalaciones costeras; componentes eléctricos tropicalizados para temperatura ambiente de 55 °C; envolventes acústicas con clasificación IP54 que reducen el ruido de 85 dB(A) a 72 dB(A) a 1 metro.
- Fabricantes de equipos originales y marcas privadas: Colores de pintura personalizados, placas de identificación con la marca y paquetes de documentación localizados para distribuidores de equipos de gas e integradores de sistemas.
Las configuraciones personalizadas están disponibles en Cantidad mínima de pedido: 1 unidadLa revisión de ingeniería y la elaboración de propuestas suelen requerir de 5 a 7 días hábiles. El plazo de entrega estándar es de 12 a 14 semanas; los pedidos repetidos se entregan en un plazo de 8 a 10 semanas a partir de la confirmación del pedido.
Case Study: Chemical Synthesis Plant Nitrogen Injection Upgrade
Cliente: A specialty chemical manufacturer in Indonesia operating high-pressure batch reactors for polymer production
Desafío: The plant required ultra-high-pressure nitrogen (2.80–3.00 MPa) for reactor inerting and catalyst bed preservation during batch polymerization cycles. Their existing oil-lubricated compressor (imported European brand, 12 years in service) was experiencing severe oil carryover into the nitrogen stream, with contamination levels reaching 5.2 mg/m³. This oil contamination was poisoning the Ziegler-Natta polymerization catalyst, reducing catalyst efficiency by 30% and causing off-specification polymer batches. The oil was also fouling the reactor heat transfer surfaces, requiring quarterly chemical cleaning. Annual maintenance costs had escalated to $65,000.
Solución: Suministramos un 3ZW-6/30 oil-free nitrogen compressor as the primary high-pressure nitrogen source, configured on a custom skid with three integrated intercoolers, aftercooler, and a Siemens S7-1200 PLC control panel with stage-by-stage pressure monitoring. The 3.00 MPa discharge pressure met the reactor inerting requirements with a safety margin. The oil-free design eliminated catalyst poisoning and reactor fouling. A 2 m³ surge vessel was installed upstream to buffer demand fluctuations from the batch reactor cycle.
Resultados cuantificados después de 18 meses:
- Contenido de nitrógeno en el aceite: Reduced from 5.2 mg/m³ to <0.01 mg/m³, logrando la norma ISO 8573-1 Clase 0
- Catalyst efficiency: Restored to 95% (from 65%), reducing catalyst consumption by 32%
- Off-specification batches: Eliminado por completo, saving $45,000/year in rework costs
- Reactor cleaning frequency: Se redujo de trimestral a anual., saving $18,000/year
- Coste de mantenimiento anual: Reducido en 48% ($65,000 to $33,800)
- Periodo de recuperación de la inversión: 1.6 years based on catalyst savings, rework elimination, and maintenance reduction
“The 3ZW-6/30 has transformed our polymerization process. The elimination of oil contamination has restored our catalyst performance to design levels and eliminated our off-spec batch problem. Our maintenance team now spends their time on preventive activities rather than emergency oil-related repairs. The payback was faster than our finance team projected.” — Production Director, Specialty Chemical Plant
Preguntas frecuentes y guía de selección
Productos y soluciones relacionados
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Compresores multietapa sin aceite de la serie ZW
Compresores verticales multietapa sin aceite para oxígeno, nitrógeno, hidrógeno y gases especiales. Presiones de descarga de hasta 9,00 MPa para aplicaciones de llenado de gas a ultra alta presión y procesos químicos.
Compresores de nitrógeno de gran capacidad de la serie LW
Compresores de pistón sin aceite de alto caudal (20–130 m³/min) para respaldo de unidades de separación de aire criogénicas, refuerzo de sistemas de bombeo de vapor y distribución por tuberías industriales. Presiones de descarga de 0,30 a 0,80 MPa.
Para obtener una descripción general completa de nuestros compresor de nitrógeno industrial Para obtener más información sobre nuestra cartera de productos, que incluye compresores de oxígeno sin aceite, compresores de hidrógeno, compresores de dióxido de carbono y soluciones de gases especiales diseñadas a medida, póngase en contacto con nuestro equipo de ingeniería de aplicaciones o consulte nuestro catálogo de productos en línea.
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