설명
ZW-5.3/16 Nitrogen Compressor – High-Pressure Oil-Free N2 Booster for 1.60 MPa Industrial Applications
Engineered to deliver 5.3 m³/min at 1.60 MPa discharge pressure, the ZW-5.3/16 is a two-stage, three-row oil-free piston nitrogen compressor purpose-built for high-pressure nitrogen injection, cylinder filling, and demanding petrochemical process applications. Zero oil contamination, compact footprint, and optimized for continuous-duty operation at elevated pressure.
제품 개요
그만큼 ZW-5.3/16 nitrogen compressor represents a specialized high-pressure solution within our oil-free piston compressor family, engineered for applications where elevated discharge pressure is the primary operational requirement. With a rated capacity of 5.3 m³/min 그리고 탁월한 1.60 MPa discharge pressure, this unit occupies a unique position in the industrial nitrogen compression landscape—bridging the gap between conventional low-pressure boosters and ultra-high-pressure gas filling systems.
What distinguishes the ZW-5.3/16 from conventional alternatives is its 완전 무오일 압축 메커니즘 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 high-purity nitrogen cylinder filling, pharmaceutical-grade nitrogen injection, and electronics process gas supply without additional downstream purification equipment. The oil-free certification is particularly critical at 1.60 MPa because oil contamination at elevated pressure becomes more difficult and costly to remove.
Its two-stage, three-row (二列三级) configuration delivers the high pressure ratio required for 1.60 MPa discharge while managing thermal loads through staged intercooling. The compact dimensions—1947 × 1900 × 2580 mm—allow the ZW-5.3/16 to fit into existing machinery rooms or containerized installations where floor space is at a premium. At 3.97 tonnes, the unit can be transported and positioned using standard forklift equipment.
Technical Specifications – ZW-5.3/16
| 매개변수 | 값 | 단위 |
|---|---|---|
| 모델 | ZW-5.3/16 | – |
| 무늬 | Two-stage, Three-row (二列三级) | – |
| 용량 | 5.3 | m³/min |
| 토출 압력 | 1.60 | MPa |
| 압축기 크기 (길이 × 너비 × 높이) | 1947 × 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. 고압 무유 PTFE 밀봉 기술
The ZW-5.3/16 employs a proprietary self-lubricating piston ring and rider band system manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates, specifically formulated for high-pressure service. This material achieves a coefficient of friction below 0.08 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover into the nitrogen stream. At 1.60 MPa, the risk of oil contamination becomes exponentially more problematic because oil droplets are more difficult to separate at elevated pressure, and any contamination becomes concentrated in the compressed gas. The ZW-5.3/16’s native oil-free design achieves ISO 8573-1 Class 0 compliance without downstream filtration, a critical advantage for cylinder filling and high-purity process applications.
2. Two-Stage Three-Row Compression Architecture
그만큼 two-stage, three-row configuration of the ZW-5.3/16 is uniquely engineered to achieve the high pressure ratio required for 1.60 MPa discharge. The three-row arrangement provides superior force balance compared to two-row designs, reducing vibration transmission and permitting installation on lighter foundations. The staged compression with inter-stage cooling limits the discharge temperature of each stage to below 160°C, preserving the integrity of the PTFE sealing elements and extending valve plate life. This thermal management is particularly critical at high pressure ratios where adiabatic compression temperatures would otherwise exceed the safe operating limits of polymer-based seals.
3. Compact Design for Space-Constrained Installations
At 1947 × 1900 × 2580 mm, the ZW-5.3/16 occupies remarkably little floor space for a high-pressure compressor of this capability. The compact footprint is achieved through an optimized vertical crankcase design that minimizes the machine’s longitudinal dimension while maintaining adequate maintenance access. The 3.97-tonne weight permits transportation and positioning using standard forklift equipment, eliminating the need for overhead cranes or specialized rigging. This portability makes the ZW-5.3/16 ideal for containerized nitrogen supply systems, mobile cylinder filling stations, and retrofit installations in existing compressor houses with limited floor space.
4. Standard 380V Direct-On-Line Motor Drive
The ZW-5.3/16 is powered by a 55 kW, 380V, 50Hz three-phase induction motor 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-5.3/16 an attractive option for facilities upgrading from bottled nitrogen or membrane generators to on-site high-pressure compression.
응용 시나리오
High-Pressure Nitrogen Cylinder Filling
The ZW-5.3/16 is purpose-built for nitrogen cylinder filling stations serving industrial gas distributors, welding supply companies, and specialty gas laboratories. Its 1.60 MPa discharge pressure is sufficient to fill standard industrial nitrogen cylinders to 15 MPa working pressure through a high-pressure booster or cascade system. The 5.3 m³/min capacity supports a filling rate of approximately 20–25 cylinders per hour (40L, 15 MPa), making it suitable for medium-volume filling operations. The oil-free design is mandatory for cylinder filling because any oil contamination would be concentrated in the compressed gas and could contaminate downstream processes when the cylinder is used.
Petrochemical High-Pressure Nitrogen Injection
In petrochemical and refinery operations, the ZW-5.3/16 provides high-pressure nitrogen for reactor inerting, catalyst preservation, emergency vessel purging, and pipeline pressure testing. The 1.60 MPa discharge pressure is sufficient to overcome the pressure ratings of most process vessels and reactor systems, allowing direct nitrogen injection without intermediate boosting. The ZW-5.3/16 high-pressure nitrogen compressor is particularly valuable for emergency response scenarios where rapid nitrogen injection is required to inert a vessel or suppress a runaway reaction. The oil-free certification is mandatory because nitrogen at 1.60 MPa entering a catalyst bed or process stream must remain completely hydrocarbon-free.
Pharmaceutical & Biotechnology Process Gas
Pharmaceutical manufacturing facilities require high-purity nitrogen for sterile process inerting, lyophilization (freeze-drying), and aseptic filling operations. The ZW-5.3/16’s oil-free certification ensures compliance with FDA 21 CFR, EU GMP Annex 1, and pharmacopeial nitrogen standards. The 1.60 MPa pressure is adequate for feeding high-pressure nitrogen distribution manifolds serving multiple sterile processing suites, autoclaves, and freeze-dryers. The compact footprint allows installation within pharmaceutical cleanroom support areas or utility corridors where space is severely constrained.
Electronics & Semiconductor Manufacturing
Semiconductor fabrication facilities require high-pressure nitrogen for wafer handling systems, chemical vapor deposition (CVD) processes, and ion implantation chamber purging. The ZW-5.3/16’s 1.60 MPa discharge pressure is sufficient for feeding the high-pressure nitrogen headers that serve process tools requiring elevated pressure for pneumatic actuation or process gas delivery. The oil-free design is absolutely non-negotiable in semiconductor applications because even trace oil contamination can cause catastrophic defects in integrated circuits, leading to yield losses measured in millions of dollars.
자재 및 시공
The ZW-5.3/16 is constructed from premium materials selected for high-pressure nitrogen compatibility, corrosion resistance, and extended operational life:
| 요소 | 재료 | 사양 |
|---|---|---|
| 실린더 블록 | 회색 주철 | GG25 / HT250, integral cooling passages |
| 크랭크 샤프트 | 단조 합금강 | 42CrMo4, Q&T, dynamically balanced |
| 피스톤 링 | PTFE-유리-청동 복합재 | Self-lubricating, high-pressure rated to 2.0 MPa |
| 라이더 밴드 | PTFE 복합재 | Piston guidance, anti-scuffing, wear rate <0.05 mm/1000h |
| 밸브 플레이트 | 스테인리스 스틸 | SS316, 고압 동심 링 설계 |
| 커넥팅 로드 | 배빗 베어링이 적용된 단조강 | 정밀 가공 및 오일 윤활 방식의 빅 엔드 |
| 인터쿨러 | 탄소강 쉘 / SS316 튜브 | ASME VIII Div.1, 1.5× hydrotest |
| 애프터쿨러 | 탄소강 쉘 / SS316 튜브 | 고압 핀 튜브, 32°C 냉각수 |
| 고압 배관 | 이음매 없는 스테인리스 스틸 | SS316, rated to 2.5 MPa working pressure |
All pressure-bearing components are designed and fabricated in accordance with ASME BPVC 섹션 VIII 부문 1 또는 중국 GB 150 표준을 준수합니다. 모든 용접 이음매는 ASME 섹션 V, 2항에 따라 100% 방사선 투과 검사(RT)를 거치며, 완성된 모든 압력 용기는 최대 허용 작동 압력(MAWP)의 1.5배에 해당하는 압력으로 최소 30분 동안 수압 시험을 거칩니다.
설치 및 유지 관리 지침
Foundation & Spatial Requirements
The ZW-5.3/16 weighs 3.97 tonnes and features a compact vertical design with a low center of gravity. A reinforced concrete pad of 5–6 tonnes is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The three-row opposed-cylinder arrangement provides excellent force balance, minimizing vibration transmission. Required clearances: 1.0 m on the non-drive side for valve maintenance, 0.8 m on the drive side for motor access, and 1.5 m overhead for routine service.
Cooling Water Specifications
냉각수 수요는 대략 다음과 같습니다. 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Water quality specifications: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride content < 50 mg/L (to prevent SS316 tube corrosion), suspended solids < 30 mg/L. For installations without reliable municipal water, a compact closed-loop cooling tower with a 0.5 m³ buffer tank is recommended.
예방 정비 일정
| 간격 | 서비스 항목 | 조치 필요 |
|---|---|---|
| 일일 | Visual & Operational Check | Inspect for leaks, abnormal noise, cooling water flow, discharge temperature |
| 250시간 | 밸브 플레이트 검사 | Check for carbon deposits, spring fatigue, or cracking in high-pressure valves |
| 1,000시간 | 피스톤 링 마모 평가 | Measure groove clearance; replace rings if clearance exceeds 0.20 mm |
| 3,000시간 | 중간 정비 | 피스톤 링, 라이더 밴드 및 밸브 플레이트 어셈블리를 모두 교체하십시오. |
| 6,000시간 | 대대적인 개편 | Inspect crankshaft, measure bearing clearances, replace bearings if >0.08 mm |
The oil-free design of the ZW-5.3/16 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. The only consumable wear items are the PTFE 피스톤 링 및 라이더 밴드, which typically achieve 3,000–5,000 hours of service under clean nitrogen conditions at high pressure.
규정 준수 및 안전 인증
The ZW-5.3/16 nitrogen compressor meets the following international standards and regulatory requirements:
ASME BPVC 섹션 VIII Div.1, GB 150-2011, PED 2014/68/EU 모듈 A
IEC 60034-1 (IE3 efficiency), IEC 60204-1, ISO 12100
ISO 8573-1 Class 0 (Oil Content), TÜV Rheinland tested
ISO 9001:2015, ISO 14001:2015
Nitrogen is an odorless, colorless asphyxiant gas. At 1.60 MPa, nitrogen releases from the ZW-5.3/16 can create high-velocity jets that rapidly displace oxygen in enclosed spaces. All installations must include continuous oxygen deficiency monitoring, emergency ventilation systems, and personnel training on nitrogen hazard awareness. Emergency shutdown interlocks should activate at 19.5% O₂ (alarm) and trigger hard shutdown at 18.0% O₂.
성과 및 효율성 분석
The ZW-5.3/16 achieves a specific power consumption of approximately 10.38 kW per m³/min of nitrogen at 1.60 MPa discharge pressure. While this specific power is higher than low-pressure models due to the elevated pressure ratio, it remains competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated reciprocating compressors at equivalent pressure ratios typically consume 11–13 kW/m³/min, and diaphragm compressors (often selected for high-pressure oil-free service) may exceed 15 kW/m³/min.
The primary economic advantage of the ZW-5.3/16 is not marginal energy savings but the elimination of oil-related consumables and downstream purification equipment. A typical oil-lubricated high-pressure compressor requires quarterly oil changes ($300–600/year), monthly oil analysis ($200–400/year), annual filter replacements ($500–1,000/year), and separator cartridge changes ($800–1,500/year). The ZW-5.3/16 eliminates all of these expenses, delivering total consumable savings of $1,800–$3,500 annually.
Additionally, the 고압 질소 압축의 총 소유 비용 is further reduced by eliminating the need for downstream oil-removal equipment. At 1.60 MPa, oil-filtration systems become significantly more complex and expensive, often requiring multi-stage coalescing filters followed by activated carbon adsorbers. The ZW-5.3/16’s native oil-free design removes this capital and operating burden entirely.
맞춤 제작 및 OEM 역량
We provide flexible customization options to adapt the ZW-5.3/16 to specific installation constraints and end-user requirements:
- Skid-Mounted Packages: Pre-assembled compressor, motor, coolers, and control panel on a structural steel skid with forklift pockets and lifting eyes. Reduces field installation to electrical and cooling water connections only.
- Mobile Cylinder Filling Stations: The ZW-5.3/16 can be mounted on a road-legal trailer with integrated nitrogen storage, cylinder filling manifold, and diesel generator, creating a fully mobile high-pressure nitrogen supply unit for construction sites and emergency response.
- PLC & Remote Monitoring: Optional Siemens LOGO! or S7-1200 PLC with HMI touchscreen, Ethernet connectivity, and SMS/email alarm notifications. Compatible with Modbus TCP/IP for SCADA integration.
- Acoustic Enclosures: Compact IP54-rated sound enclosure reducing noise from 84 dB(A) to 68 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments.
- OEM 및 자체 브랜드: Custom paint schemes, branded nameplates, and localized documentation for gas equipment distributors and system integrators.
사용자 지정 구성은 다음에서 이용 가능합니다. 최소 주문 수량 1개. Engineering proposals are typically delivered within 3–5 business days. Standard delivery is 10–12 weeks; expedited delivery within 8 weeks is available.
Case Study: Nitrogen Cylinder Filling Station Upgrade
고객: An industrial gas distributor in Thailand serving welding, food packaging, and pharmaceutical customers
도전: The client’s existing oil-lubricated compressor (12 years in service) was experiencing oil carryover into filled nitrogen cylinders, causing customer complaints from pharmaceutical clients and requiring expensive cylinder cleaning procedures. The compressor was also undersized for growing demand, creating bottlenecks during peak filling periods.
해결책: We supplied a ZW-5.3/16 oil-free nitrogen compressor configured on a custom skid with integrated intercooler, aftercooler, and a high-pressure filling manifold capable of filling 40L cylinders to 15 MPa. The compact skid footprint fit within the existing filling bay without structural modifications.
Results After 18 Months:
- Cylinder oil contamination: 완전히 제거됨, achieving ISO 8573-1 Class 0 in all filled cylinders
- 고객 불만 사항: 영 related to oil contamination or cylinder quality
- Filling capacity: Increased by 35%, reducing peak-period bottlenecks
- Maintenance costs: Reduced by 40% through elimination of oil-related repairs and filter changes
- Cylinder cleaning expenses: Eliminated, saving $8,000/year
“The ZW-5.3/16 has completely transformed our cylinder filling operation. No more oil contamination issues, no more customer complaints, and our maintenance team spends half the time on compressor service. The payback was under 2 years.” — Operations Manager, Industrial Gas Distributor
자주 묻는 질문 및 선택 가이드
관련 제품 및 솔루션
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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.
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Medium-pressure oil-free compressors (1.0–4.0 MPa) for nitrogen recycle, gas liquefaction, and process gas compression in petrochemical operations.
For a complete overview of our 산업용 질소 압축기 portfolio, including oil-free oxygen compressors, hydrogen compressors, and specialty gas solutions, please contact our engineering team.
고압 질소 시스템 업그레이드를 고려하고 계신가요?
Our application engineers are available to evaluate your high-pressure nitrogen requirements, inlet conditions, and integration constraints. We provide complimentary technical proposals, layout drawings, and TCO analyses within 48 hours.
이메일: [email protected] 24시간 이내 답변드리겠습니다.
