Kompresor Nitrogen ZW-8/6 – Booster N2 Bebas Oli Ringkas untuk Sistem Gas Industri Tekanan Rendah

Dirancang untuk menghasilkan 8 m³/menit pada tekanan keluaran 0,60 MPa, ZW-8/6 adalah kompresor nitrogen piston bebas oli dua tahap, dua baris yang dirancang untuk pemisahan udara kriogenik skala kecil, pasokan nitrogen laboratorium, dan stasiun penguat VPSA kompak. Tidak ada kontaminasi oli, ukuran yang hemat ruang, dan dioptimalkan untuk pengoperasian sesekali hingga terus menerus.

Gambaran Umum Produk

Itu ZW-8/6 nitrogen compressor represents a compact yet capable solution within our oil-free piston compressor family, specifically tailored for small-scale nitrogen boosting applications where space constraints and operational simplicity are paramount. With a rated capacity of 8 m³/min dan tekanan pelepasan sebesar 0.60 MPa, this unit occupies the entry-level segment of our industrial nitrogen compressor portfolio while maintaining the same engineering rigor as our larger models.

The ZW-8/6 distinguishes itself through a mekanisme kompresi yang sepenuhnya bebas oli utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, making the unit immediately suitable for laboratory-grade nitrogen, small-batch food packaging, pharmaceutical R&D, and electronics assembly line inerting without additional downstream purification equipment.

Dia dua tahap, dua baris (二列二级) configuration delivers a higher pressure ratio than single-stage alternatives while maintaining thermal stability through inter-stage cooling. The compact dimensions—2250 × 1296 × 2200 mm—allow the ZW-8/6 to fit into existing machinery rooms, containerized installations, or mobile nitrogen supply skids where floor space is at a premium. At just 2.00 tonnes, the unit can be transported and positioned without heavy-lift equipment.

Technical Specifications – ZW-8/6

* Semua spesifikasi dinilai pada kondisi referensi standar (ISO 1217, Lampiran C). Kinerja aktual dapat bervariasi berdasarkan ketinggian lokasi, suhu lingkungan, dan kondisi saluran masuk.

Fitur Utama & Keunggulan Teknik

1. Compact Footprint for Space-Constrained Installations

Pada 2250 × 1296 × 2200 mm, the ZW-8/6 occupies less than 3 m² of floor space, making it one of the most compact oil-free nitrogen compressors in its capacity class. This dimensional efficiency is achieved through a vertically oriented crankcase design that minimizes the machine’s longitudinal footprint while maintaining adequate maintenance access. The 2.00-tonne weight permits installation using standard forklift equipment, eliminating the need for overhead cranes or specialized rigging during commissioning or relocation.

2. Oil-Free PTFE Sealing Technology

The ZW-8/6 employs a sistem ring piston dan sabuk penggerak yang melumasi sendiri constructed from high-performance PTFE composites. These rings operate with a coefficient of friction below 0.08 without any hydrocarbon lubricant, delivering Kandungan minyak ISO 8573-1 Kelas 0 in the compressed nitrogen stream. For small-scale users such as analytical laboratories, food R&D facilities, and electronics manufacturers, this native oil-free certification eliminates the capital expense and maintenance burden of downstream oil-filtration systems that would otherwise be mandatory.

3. Two-Stage Compression for Higher Pressure Ratios

Itu two-stage, two-row architecture divides the pressure ratio between a low-pressure cylinder and a high-pressure cylinder, with an inter-stage shell-and-tube cooler removing the heat of compression. This staged approach limits the discharge temperature of each stage to below 150°C, preventing thermal degradation of the PTFE sealing elements and extending valve plate life by approximately 30% compared to single-stage compressors operating at equivalent overall pressure ratios. The 0.60 MPa discharge pressure is particularly well-suited for medium-pressure nitrogen distribution in small industrial facilities.

4. Penggerak Motor Langsung Standar 380V

The ZW-8/6 is powered by a Motor induksi tiga fasa 55 kW, 380V, 50Hz rated to IEC 60034-1 IE3 efficiency class. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage infrastructure, step-down transformers, or specialized switchgear. This electrical simplicity reduces both capital expenditure and commissioning complexity, making the ZW-8/6 an attractive option for facilities upgrading from bottled nitrogen or membrane generators to on-site compression.

Skenario Aplikasi

Small-Scale Cryogenic Air Separation Units

In compact cryogenic ASU installations producing 200–500 Nm³/h of gaseous nitrogen, the ZW-8/6 serves as the penguat nitrogen utama between the cold box and the distribution network. Its 8 m³/min capacity aligns with the output of small-scale ASUs, while the 0.60 MPa discharge pressure provides sufficient head for distribution to nearby process equipment, laboratory fume hoods, or storage tank blanketing systems. The oil-free design is critical in these applications because small ASUs typically lack the extensive purification trains found in large facilities, making downstream oil contamination particularly problematic.

Compact VPSA Nitrogen Booster Stations

For small to medium VPSA nitrogen generators producing 99.5–99.9% purity nitrogen at near-atmospheric pressure, the ZW-8/6 nitrogen booster compresses the low-pressure product to 0.60 MPa for distribution. The compact footprint of the ZW-8/6 allows it to be mounted on the same skid as the VPSA generator, creating a fully integrated nitrogen supply system that occupies minimal floor space. The oil-free compression path protects the carbon molecular sieve from hydrocarbon poisoning, preserving the generator’s separation efficiency and extending adsorbent life.

Laboratory & Analytical Gas Supply

Research laboratories, analytical chemistry facilities, and university science departments require a reliable supply of high-purity nitrogen for gas chromatography, mass spectrometry, and inert atmosphere glove boxes. The ZW-8/6’s oil-free certification ensures that the nitrogen stream meets the stringent purity requirements of analytical instruments without requiring additional purification cartridges. The 8 m³/min capacity can support multiple GC-MS systems, ICP-MS instruments, and glove boxes operating simultaneously within a single laboratory building.

Electronics Manufacturing & Soldering Inerting

Di fasilitas perakitan elektronik, nitrogen digunakan untuk wave soldering inerting, reflow oven atmosphere control, and component storage dry cabinets. The ZW-8/6’s 0.60 MPa discharge pressure is adequate for feeding nitrogen distribution manifolds serving multiple soldering lines and storage cabinets. The oil-free design is non-negotiable in electronics applications because even trace oil contamination can cause solder joint defects, conformal coating adhesion failures, and contamination of sensitive optical components.

Bahan & Konstruksi

The ZW-8/6 is constructed from materials selected for nitrogen compatibility, corrosion resistance, and compact structural integrity:

All pressure-bearing components conform to ASME BPVC Bagian VIII Divisi 1 or Chinese GB 150 standards. Weld joints are subjected to 100% radiographic inspection (RT), and each pressure vessel undergoes hydrostatic testing at 1.5× MAWP for a minimum 30-minute hold period before release.

Panduan Pemasangan & Pemeliharaan

Persyaratan Pondasi & Spasial

The ZW-8/6 weighs 2.00 tonnes and features a low center of gravity due to its compact vertical design. A reinforced concrete pad of 3–4 tonnes Cukup untuk pengoperasian yang stabil, dipasang pada isolator getaran elastomer (frekuensi alami 8–12 Hz). Susunan silinder berlawanan dua baris secara inheren membatalkan gaya inersia orde pertama, meminimalkan transmisi getaran. Jarak bebas yang dibutuhkan: 1,0 m di sisi non-penggerak untuk perawatan katup, 0,8 m di sisi penggerak untuk akses motor, dan 1,5 m di atas untuk servis rutin.

Spesifikasi Air Pendingin

Kebutuhan air pendingin kira-kira 12 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Acceptable water quality: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride < 50 mg/L, suspended solids < 30 mg/L. For installations without reliable municipal water supply, a compact closed-loop cooling tower with a 1 m³ buffer tank is recommended.

Maintenance Intervals

The oil-free design of the ZW-8/6 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes to schedule, no oil samples to analyze, no filter elements to replace, and no oil separator cartridges to monitor. The only consumable wear items are the Ring piston PTFE dan sabuk penggerak, which typically achieve 4,000–6,000 hours of service under clean nitrogen conditions.

Sertifikasi Kepatuhan & Keselamatan

The ZW-8/6 nitrogen compressor meets the following international standards and regulatory requirements:

Analisis Kinerja & Efisiensi

The ZW-8/6 achieves a specific power consumption of approximately 6.88 kW per m³/min of nitrogen at 0.60 MPa discharge pressure. While this specific power is higher than our larger LW-series models due to the reduced scale efficiency, it remains competitive within the sub-10 m³/min oil-free piston compressor segment. For comparison, oil-lubricated screw compressors in this size range typically consume 7.2–8.0 kW/m³/min, and diaphragm compressors (often selected for oil-free applications) can exceed 10 kW/m³/min.

Over an 8,000-hour annual operating cycle, the ZW-8/6’s efficiency advantage versus less efficient alternatives yields approximately 20,000–45,000 kWh of energy savings per year. At $0.08/kWh, this represents $1,600–$3,600 in annual electricity cost reduction. However, the primary economic driver for ZW-8/6 selection is typically the penghapusan bahan habis pakai terkait minyak dan peralatan pemurnian hilir alih-alih penghematan energi yang marginal.

Itu total biaya kepemilikan untuk kompresi nitrogen in small-scale applications is dominated by maintenance labor and consumables rather than energy. The ZW-8/6’s oil-free design eliminates oil changes ($400–800/year), filter replacements ($200–400/year), separator cartridge changes ($600–1,200/year), and oil analysis ($150–300/year), delivering a total consumable savings of $1,350–$2,700 annually compared to lubricated alternatives.

Kemampuan Kustomisasi & OEM

We provide flexible customization options to adapt the ZW-8/6 to specific installation constraints and end-user requirements:

• Paket yang Dipasang di Atas Rangka: Kompresor, motor, pendingin, dan panel kontrol yang telah dirakit sebelumnya pada rangka baja struktural dengan kantong forklift dan lubang pengangkat. Mengurangi instalasi di lapangan hanya menjadi sambungan listrik dan sambungan air pendingin.
• Unit Trailer Bergerak: The ZW-8/6 can be mounted on a road-legal trailer with integrated diesel generator, cooling system, and nitrogen storage, creating a fully mobile nitrogen supply unit for construction sites, pipeline maintenance, and emergency response.
• PLC & Pemantauan Jarak Jauh: PLC Siemens LOGO! atau S7-1200 opsional dengan layar sentuh HMI 7 inci, konektivitas Ethernet, dan notifikasi alarm SMS/email. Kompatibel dengan Modbus TCP/IP untuk integrasi SCADA.
• Ruang Kedap Suara: Kotak kedap suara berukuran kompak dengan peringkat IP54 yang mengurangi kebisingan dari 82 dB(A) menjadi 68 dB(A) pada jarak 1 meter, cocok untuk instalasi dalam ruangan di lingkungan yang sensitif terhadap kebisingan seperti laboratorium dan ruang mesin yang berdekatan dengan kantor.
• OEM & Private Label: Skema pengecatan khusus, pelat nama bermerek, dan paket dokumentasi lokal untuk distributor peralatan gas dan integrator sistem.

Konfigurasi khusus tersedia dari MOQ 1 unitProposal rekayasa biasanya dikirim dalam waktu 3–5 hari kerja. Waktu pengiriman standar adalah 10–12 minggu; pengiriman dipercepat dalam waktu 8 minggu tersedia untuk pesanan yang memenuhi syarat.

Case Study: Laboratory Nitrogen Supply Upgrade

Klien: A pharmaceutical research institute in Singapore

Tantangan: The institute was purchasing liquid nitrogen in 200-liter dewars and vaporizing on-site for laboratory supply. Monthly nitrogen consumption reached 15,000 Nm³, with delivery costs, dewar rental fees, and vaporization losses consuming 40% of the annual gas budget. Additionally, liquid nitrogen deliveries were unreliable during public holidays and inclement weather, causing experiment delays.

Larutan: Kami menyediakan ZW-8/6 oil-free nitrogen compressor paired with a small VPSA nitrogen generator (99.9% purity, 10 m³/min) on a common skid. The ZW-8/6 boosts the VPSA product from 0.08 MPa to 0.60 MPa for distribution through the existing laboratory nitrogen header. The entire system occupies 8 m² in a corner of the building’s utility room.

Hasil Setelah 18 Bulan:

• Nitrogen supply cost: Dikurangi sebesar 52% versus liquid nitrogen purchase and delivery
• Supply reliability: 100% uptime since commissioning, zero experiment delays due to gas shortage
• Kemurnian nitrogen: Consistently >99.9% with oil content <0.01 mg/m³, exceeding analytical instrument requirements
• Beban pemeliharaan: Satu kali servis terjadwal per tahun (4,000-hour interval), versus monthly dewar changeovers
• Periode pengembalian modal: 2.4 years based on gas cost savings alone

“The ZW-8/6 compressor has transformed our nitrogen supply from a logistical headache into a reliable utility. Our researchers no longer worry about gas availability, and the finance department appreciates the 50% cost reduction.” — Facilities Manager, Pharmaceutical Research Institute

FAQ & Panduan Seleksi

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