설명
ZW-3/50 Nitrogen Compressor – Ultra-High-Pressure Oil-Free N2 Booster for 5.00 MPa Critical Process Applications
Engineered to deliver 3 m³/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.
제품 개요
그만큼 ZW-3/50 nitrogen compressor 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 m³/min 그리고 탁월한 5.00 MPa discharge pressure, this unit addresses the most demanding nitrogen compression requirements in specialized industrial and research applications.
What distinguishes the ZW-3/50 from conventional alternatives is its fully oil-free compression pathway 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.
압축기는 다음을 사용합니다. two-stage, three-row (二列三级) 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.
Technical Specifications – ZW-3/50
| 매개변수 | 값 | 단위 |
|---|---|---|
| 모델 | ZW-3/50 | – |
| 무늬 | Two-stage, Three-row (二列三级) | – |
| 용량 | 3 | m³/min |
| 토출 압력 | 5.00 | MPa |
| 압축기 크기 (길이 × 너비 × 높이) | 1920 × 1900 × 2580 | mm |
| 무게 | 3.97 | 티 |
| 힘 | 55 | 킬로와트 |
| 전압 | 380 | 다섯 |
| 가스 매체 | 질소(N₂) | – |
| 매끄럽게 하기 | 오일 프리 | – |
* 모든 사양은 표준 참조 조건(ISO 1217, 부록 C)에서 측정되었습니다. 실제 성능은 현장 고도, 주변 온도 및 흡입구 조건에 따라 달라질 수 있습니다.
주요 특징 및 엔지니어링 장점
1. Ultra-High-Pressure Oil-Free PTFE Sealing System
The ZW-3/50 utilizes a proprietary 자가 윤활 피스톤 링 및 라이더 밴드 어셈블리 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°C, ensuring reliable sealing integrity even under the extreme thermal stress of ultra-high-pressure compression.
2. Three-Row Design for Superior Force Balance
그만큼 two-stage, three-row (二列三级) 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 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.
3. Reinforced High-Pressure Frame Construction
본체는 다음 재료로 주조됩니다. GG30 gray cast iron (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 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—stricter than the G2.5 standard used for lower-pressure compressors.
4. Standard 380V Drive with High-Torque Motor
The ZW-3/50 is driven by a 55 kW, 380V, 50Hz three-phase induction motor 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.
응용 시나리오
Ultra-High-Pressure Nitrogen Cylinder Cascade Filling
The ZW-3/50 is ideally suited for cylinder filling stations 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 0.05–0.10 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.
Critical Petrochemical Emergency Nitrogen Injection
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. 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 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.
Supercritical Fluid Extraction & Processing
Supercritical fluid extraction (SFE) processes using nitrogen require pressures in the range of 3.0–7.0 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. 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 m³/min capacity is well-matched to pilot-scale and small production-scale SFE systems.
High-Pressure Pipeline Pressure Testing & Purging
Natural gas pipelines, hydrogen pipelines, and high-pressure process piping require nitrogen pressure testing and purging 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× 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.
자재 및 시공
The ZW-3/50 is constructed from premium materials specifically selected for ultra-high-pressure nitrogen service, thermal resistance, and extreme mechanical integrity:
| 요소 | 재료 | 사양 |
|---|---|---|
| 실린더 블록(LP) | 회색 주철 | GG30 / HT300, standard wall thickness |
| 실린더 블록(마력) | 회색 주철 | GG30 / HT300, heavy wall + reinforced ribbing |
| 크랭크 샤프트 | 단조 합금강 | 42CrMo4, Q&T, ISO 1940 G1.0 balanced |
| 피스톤 링 | PTFE-유리-청동 복합재 | Ultra-high-pressure rated, self-lubricating, 185°C max |
| 라이더 밴드 | PTFE 복합재 | Piston guidance, anti-scuffing, wear rate <0.03 mm/1000h |
| 밸브 플레이트 | 스테인리스 스틸 | SS316, ultra-high-pressure concentric ring design |
| 커넥팅 로드 | 배빗 베어링이 적용된 단조강 | 정밀 가공 및 오일 윤활 방식의 빅 엔드 |
| 인터쿨러 | 탄소강 쉘 / SS316 튜브 | ASME VIII Div.1, 1.5배 수압 시험, 30분 유지 |
| 애프터쿨러 | 탄소강 쉘 / SS316 튜브 | 고압 핀 튜브, 32°C 냉각수 |
| 고압 배관 | 이음매 없는 스테인리스 스틸 | SS316, ANSI Class 900 flanges |
| 기본 프레임 | Heavy Structural Steel | Welded, reinforced, vibration-damped mounting |
모든 압력 지지 부품은 다음 사항에 따라 엄격하게 설계 및 제작됩니다. ASME BPVC 섹션 VIII 부문 1 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.
설치 및 유지 관리 지침
기초 및 구조 요구사항
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 reinforced concrete inertia block of 6–8 tonnes mounted on heavy-duty elastomeric vibration isolators (natural frequency 6–8 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.
냉각수 시스템 설계
냉각수 수요는 대략 다음과 같습니다. 14 m³/h at an inlet temperature not exceeding 32°C. 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 6.5–8.5, 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 CaCO₃. 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.
예방 정비 일정
| 간격 | 서비스 항목 | 조치 필요 |
|---|---|---|
| 일일 | 운영 점검 | Check vibration, abnormal noise, cooling water flow, discharge pressure, temperature, safety valve status |
| 200 hours | 밸브 플레이트 검사 | Remove and inspect suction/discharge valves for carbon deposits, spring fatigue, cracking, seat wear |
| 800 hours | 피스톤 링 마모 평가 | Measure ring groove clearance; replace rings if clearance exceeds 0.18 mm |
| 2,500 hours | 중간 정비 | Replace all piston rings, rider bands, and valve plate assemblies; inspect high-pressure cylinder bore |
| 5,000 hours | 대대적인 개편 | Inspect crankshaft journals, measure main bearing clearances, replace bearings if >0.06 mm; inspect frame |
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 피스톤 링 및 라이더 밴드 experience higher wear rates than in low-pressure service, with typical replacement intervals of 2,500–4,000 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.
규정 준수 및 안전 인증
The ZW-3/50 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC 섹션 VIII Div.1, GB 150-2011, PED 2014/68/EU 모듈 A
IEC 60034-1(IE3 효율), IEC 60204-1, ISO 12100 기계 안전
ISO 8573-1 0등급(유지 함량) 기준 충족, TÜV 라인란트에서 독립적으로 테스트 완료
ISO 9001:2015, ISO 14001:2015
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% O₂ (alarm) and triggering hard isolation at 18.0% O₂; (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.
성과 및 효율성 분석
The ZW-3/50 achieves a specific power consumption of approximately 18.33 kW per m³/min 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 20–25 kW/m³/min, while diaphragm compressors may exceed 30 kW/m³/min.
Over an 8,000-hour annual operating cycle, the ZW-3/50’s efficiency advantage versus less efficient alternatives yields approximately 80,000–160,000 kWh of annual energy savings. At $0.08/kWh, this represents $6,400–$12,800 in direct electricity cost reduction per year. However, the primary economic driver for ZW-3/50 selection is typically the 석유 관련 소모품의 제거 및 하류의 오일 제거 장비의 불필요화 that would be mandatory with lubricated alternatives. At 5.00 MPa, the concentration of oil contamination would be approximately 15–20 times higher than at 0.30 MPa, making downstream oil removal prohibitively expensive and technically challenging.
그만큼 total cost of ownership for ultra-high-pressure nitrogen compression 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.
맞춤 제작 및 OEM 역량
We offer comprehensive customization options to adapt the ZW-3/50 to specific site conditions, safety requirements, and integration needs:
- 스키드 장착형 턴키 패키지: Pre-assembled compressor, motor, high-pressure coolers, instrumentation, safety systems, and control panel on a reinforced structural steel skid with integrated lifting lugs and anchor bolt templates. All high-pressure piping is pre-fabricated and pressure-tested at the factory.
- 위험 지역 구성: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection, automatic ventilation interlocks, and explosion-proof instrumentation.
- Advanced Safety Systems: Dual pressure relief valves, rupture disc assemblies, automatic emergency isolation valves, and SIL-rated safety instrumented systems (SIS) for critical process applications. High-pressure alarm and shutdown interlocks with redundant sensors.
- PLC & Remote Monitoring: Siemens S7-1200 or S7-1500 PLC with 10-inch HMI touchscreen, Ethernet connectivity, and SMS/email alarms. Compatible with Modbus TCP/IP and OPC-UA for SCADA integration. Automatic load/unload and emergency shutdown sequencing.
- 환경 보호: 해안 설치용 C5-M 해양 등급 코팅; 55°C 주변 환경에 적합한 열대 지역용 전기 부품; 1미터 거리에서 소음을 85dB(A)에서 72dB(A)로 줄이는 IP54 등급 방음 인클로저.
- OEM 및 자체 브랜드: 가스 장비 유통업체 및 시스템 통합업체를 위한 맞춤형 페인트 색상, 브랜드 명판 및 현지화된 문서.
사용자 지정 구성은 다음에서 이용 가능합니다. 최소 주문 수량 1개. Engineering review and proposal generation typically require 7–10 business days due to the complexity of ultra-high-pressure design. Standard delivery time is 14–16 weeks; expedited delivery within 12 weeks is available for qualifying orders.
Case Study: Supercritical CO₂ Replacement with Nitrogen in Pharmaceutical Extraction
고객: A pharmaceutical natural products extraction company in South Korea
도전: The client was using supercritical CO₂ extraction for pharmaceutical-grade plant extracts but faced regulatory pressure to eliminate CO₂ due to its classification as a greenhouse gas and concerns about residual CO₂ in the final product. They needed to transition to supercritical nitrogen extraction, which requires pressures of 3.5–5.0 MPa. Their existing CO₂ compressor was oil-lubricated and unsuitable for nitrogen service due to oil contamination risks. Additionally, the extraction process demanded absolute purity because the extracts were used in injectable drug formulations.
해결책: We supplied a ZW-3/50 oil-free nitrogen compressor configured on a custom skid with integrated high-pressure intercooler, aftercooler, a Siemens S7-1200 PLC with safety interlocks, and an automatic emergency isolation system. The 5.00 MPa discharge pressure provided the supercritical nitrogen required for extraction, while the oil-free design ensured compliance with pharmaceutical purity standards (USP-NF Grade). A 2 m³ high-pressure buffer vessel was installed downstream to stabilize pressure during the extraction cycle.
18개월 후 정량화된 결과:
- Product purity: Extracts meet USP-NF injectable grade standards with zero oil or CO₂ contamination
- Regulatory compliance: Full compliance with Korean Ministry of Food and Drug Safety (MFDS) requirements
- CO₂ emissions: 완전히 제거됨 from the extraction process, improving corporate sustainability metrics
- Extraction yield: Improved by 8% compared to CO₂ extraction for certain plant compounds
- Customer contracts: Three new pharmaceutical clients won due to CO₂-free extraction capability
“The ZW-3/50 enabled us to make the transition from CO₂ to supercritical nitrogen extraction without compromising product quality. Our pharmaceutical customers now specifically request our nitrogen-extracted products because they know there is zero risk of CO₂ residual or oil contamination. This compressor has opened an entirely new market segment for us.” — R&D Director, Pharmaceutical Extraction Company
자주 묻는 질문 및 선택 가이드
관련 제품 및 솔루션
ZW 시리즈 다단식 무오일 압축기
Vertical and horizontal multi-stage oil-free compressors for oxygen, nitrogen, hydrogen, and specialty gases. Discharge pressures up to 9.00 MPa for ultra-high-pressure gas filling and chemical process applications.
DW 시리즈 고압 질소 압축기
Medium to high-pressure oil-free compressors (0.40–2.00 MPa) for nitrogen injection, pipeline boosting, and chemical synthesis. Capacities from 2 to 130 m³/min with multi-stage configurations.
LW 시리즈 대용량 질소 압축기
극저온 공기분리장치(ASU) 백업, VPSA 부스팅 및 산업용 파이프라인 분배에 사용되는 고유량 무오일 피스톤 압축기(20~130m³/min). 토출 압력은 0.30~0.80MPa입니다.
저희에 대한 포괄적인 개요를 보시려면 산업용 질소 압축기 오일프리 산소 압축기, 수소 압축기, 이산화탄소 압축기 및 맞춤형 특수 가스 솔루션을 포함한 당사 제품 포트폴리오에 대한 자세한 내용은 애플리케이션 엔지니어링 팀에 문의하거나 온라인 제품 카탈로그를 참조하십시오.
Ready to Deploy Ultra-High-Pressure Nitrogen?
Our application engineers are standing by to evaluate your ultra-high-pressure nitrogen requirements, including flow demands, inlet conditions, discharge pressure targets, and safety system integration. We provide complimentary technical proposals, foundation layout drawings, piping and instrumentation diagrams (P&IDs), safety system designs, and detailed total cost of ownership (TCO) analyses within 48 hours of receiving your inquiry.
이메일: [email protected] 24시간 이내 답변드리겠습니다.
