Penerangan
3ZW-9.5/30 Nitrogen Compressor – Three-Stage Oil-Free N2 Booster for 3.00 MPa High-Pressure Process Applications
Engineered to deliver 9.5 m³/min at 3.00 MPa discharge pressure, the 3ZW-9.5/30 is a three-stage, three-row oil-free piston nitrogen compressor designed for ultra-high-pressure nitrogen injection, gas cylinder filling stations, and demanding chemical process applications. Zero oil contamination, multi-stage thermodynamic optimization, and built for continuous-duty operation at extreme pressure.
Gambaran Keseluruhan Produk
Yang 3ZW-9.5/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor technology, engineered specifically for applications demanding both substantial flow capacity and ultra-high discharge pressure. With a rated capacity of 9.5 m³/min dan yang luar biasa Tekanan pelepasan 3.00 MPa, this unit occupies the high-pressure segment of our industrial nitrogen compressor portfolio, addressing the most demanding process requirements in chemical synthesis, gas cylinder filling, and high-pressure inerting operations.
What distinguishes the 3ZW-9.5/30 from conventional alternatives is its three-stage compression architecture combined with a fully oil-free compression pathway. The piston rings and rider bands in all three stages are precision-machined from advanced self-lubricating PTFE composite materials that operate without hydrocarbon lubricants. This intrinsic oil-free characteristic ensures the nitrogen stream remains completely uncontaminated, achieving Pensijilan ISO 8573-1 Kelas 0 natively. For operators in pharmaceutical manufacturing, electronics fabrication, and food-grade gas production, this eliminates the capital expenditure and ongoing maintenance burden of downstream oil-removal filtration systems that would be mandatory with lubricated alternatives.
Pemampat menggunakan three-stage, three-row (三列三级) configuration that is thermodynamically essential for achieving the 3.00 MPa discharge pressure from typical inlet conditions. The overall pressure ratio of approximately 30:1 to 60:1 is distributed across three compression cylinders, with each stage operating at a manageable pressure ratio. Independent intercoolers between stages remove the substantial heat of compression, maintaining discharge temperatures within safe operating limits and preserving the integrity of the PTFE sealing elements. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120,000 jam di bawah protokol penyelenggaraan standard.
Technical Specifications – 3ZW-9.5/30
| Parameter | Nilai | Unit |
|---|---|---|
| Model | 3ZW-9.5/30 | – |
| Corak | Three-stage, Three-row (三列三级) | – |
| Kapasiti | 9.5 | m³/min |
| Tekanan Pelepasan | 3.00 | MPa |
| Saiz Pemampat (P × L × T) | 1845 × 1660 × 2360 | mm |
| Berat | 3.50 | t |
| Kuasa | 110 | kW |
| Voltan | 380 | V |
| Medium Gas | Nitrogen (N₂) | – |
| Pelinciran | Bebas minyak | – |
* Semua spesifikasi dinilai pada keadaan rujukan standard (ISO 1217, Lampiran C). Prestasi sebenar mungkin berbeza-beza berdasarkan ketinggian tapak, suhu ambien dan keadaan salur masuk.
Ciri-ciri Utama & Kelebihan Kejuruteraan
1. Three-Stage Compression for Ultra-High Pressure
The 3ZW-9.5/30 employs a three-stage compression architecture that is thermodynamically essential for achieving 3.00 MPa discharge pressure from atmospheric or low-pressure inlet conditions. The overall pressure ratio is distributed across three compression cylinders—low-pressure, medium-pressure, and high-pressure—each operating at a pressure ratio of approximately 3:1 to 4:1. This staged approach limits the discharge temperature of each stage to below 155°C, preventing thermal degradation of the PTFE sealing elements and extending valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios. Two independent intercoolers between stages remove the heat of compression, maintaining optimal thermodynamic efficiency throughout the compression path.
2. Advanced Oil-Free PTFE Sealing for High-Pressure Service
All three compression stages utilize a proprietary pemasangan cincin omboh pelincir sendiri dan jalur penunggang manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material achieves a coefficient of friction below 0.06 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 problematic. The oil-free design achieves Pensijilan ISO 8573-1 Kelas 0 secara asli, eliminating the need for downstream coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation that would be mandatory with lubricated alternatives. The PTFE formulation is specially rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity under the extreme thermal stress of ultra-high-pressure compression.
3. Three-Row Force-Balanced Frame Design
Kerangka utama dituang dari Besi tuang kelabu GG25 (equivalent to ASTM A48 Class 30B) with reinforced wall sections and integral cooling water passages. The three-row opposed-cylinder arrangement provides progressive force cancellation across the crankshaft, with the first and third cylinders opposing the second cylinder to achieve near-complete first-order force balance. This mechanical sophistication reduces the unbalanced inertia forces transmitted to the foundation by over 85% compared to single-row designs of equivalent capacity. The result is a remarkably smooth-running high-pressure compressor that can operate on a standard reinforced concrete pad without the massive inertia blocks typically required for high-pressure reciprocating machines.
4. Standard 380V Drive with High Efficiency
The 3ZW-9.5/30 is driven by a 110 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. Despite the substantial power requirement for three-stage compression, the standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage switchgear. This electrical accessibility makes the 3ZW-9.5/30 available to a wide range of industrial facilities, from small gas filling stations to medium-scale chemical plants, without electrical infrastructure upgrades.
Senario Aplikasi
Stesen Pengisian Silinder Nitrogen Tekanan Tinggi
The 3ZW-9.5/30 is purpose-built for operasi pengisian silinder nitrogen where gas must be compressed to the 15–20 MPa pressure required for standard industrial gas cylinders. While the compressor’s 3.00 MPa discharge pressure does not reach final cylinder filling pressure directly, it serves as a highly efficient primary booster that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. The three-stage design is particularly advantageous for cylinder filling because it provides a stable, cool intermediate pressure that improves the efficiency and longevity of the final high-pressure stage. The oil-free certification is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users, potentially compromising critical processes in healthcare, electronics, and food applications.
Sintesis Kimia & Reaktor Tekanan Tinggi Inersi
In chemical process plants, the 3ZW-9.5/30 nitrogen compressor membekalkan nitrogen tekanan ultra tinggi untuk lengai reaktor tekanan tinggi, pemeliharaan lapisan pemangkin dan proses pengekstrakan bendalir superkritikal. The 3.00 MPa discharge pressure is sufficient to maintain inert atmospheres in reactors operating at pressures up to 2.5 MPa, ensuring positive nitrogen flow into the vessel even during pressure transients. The three-stage design provides excellent pressure stability, which is critical for chemical processes where nitrogen pressure fluctuations could affect reaction kinetics or product quality. The oil-free design prevents catalyst poisoning and product contamination that would occur with even trace oil carryover.
Oil & Gas Pipeline Pressure Testing
In the oil and gas industry, nitrogen is the preferred medium for hydrostatic and pneumatic pressure testing of pipelines, pressure vessels, and wellhead equipment because it is inert and avoids the corrosion and contamination risks associated with water testing. The 3ZW-9.5/30’s 3.00 MPa discharge pressure is suitable for testing pipelines and equipment rated up to API Class 600 (2.5 MPa working pressure). The oil-free design is essential because any oil contamination in the test nitrogen could be mistaken for pipeline corrosion products or residual hydrocarbons, leading to false test results and costly re-testing. The 9.5 m³/min capacity allows rapid pressurization of large-diameter pipelines, reducing test cycle time and improving project productivity.
Electronics Ultra-High-Purity Nitrogen Supply
Semiconductor fabrication facilities require nitrogen at elevated pressure for wafer transport system pressurization, chemical vapor deposition (CVD) chamber purge, and high-pressure drying of photolithography equipment. The 3ZW-9.5/30’s 3.00 MPa discharge pressure drives high-velocity nitrogen jets used in precision cleaning and particle removal applications. The oil-free design is absolutely non-negotiable in semiconductor manufacturing where even sub-ppb oil contamination can cause catastrophic defects in nanometer-scale integrated circuits. The three-stage compression provides exceptionally stable discharge pressure, which is critical for maintaining consistent process conditions in deposition and etching equipment.
Bahan & Pembinaan
The 3ZW-9.5/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, thermal resistance, and extended operational life:
| Komponen | Bahan | Spesifikasi |
|---|---|---|
| Blok Silinder (LP) | Besi Tuang Kelabu | GG25 / HT250, ketebalan dinding standard |
| Cylinder Block (MP) | Besi Tuang Kelabu | GG25 / HT250, dinding bertetulang + tulang rusuk |
| Blok Silinder (HP) | Besi Tuang Kelabu | GG25 / HT250, heavy-duty reinforced casting |
| Aci engkol | Keluli Aloi Tempa | 42CrMo4, Q&T, ISO 1940 G2.5 seimbang secara dinamik |
| Piston Rings (All Stages) | Komposit PTFE-Kaca-Gangsa | Tekanan tinggi, pelincir sendiri, maksimum 185°C |
| Kumpulan Penunggang | Komposit PTFE | Panduan omboh, anti-calar, kadar haus <0.04 mm/1000j |
| Plat Injap | Keluli Tahan Karat | SS316, reka bentuk spring cincin sepusat tekanan tinggi |
| Intercoolers (2 units) | Cangkang Keluli Karbon / Tiub SS316 | ASME VIII Div.1, ujian hidro 1.5×, tahan 30 minit |
| Penyejuk Selepas | Cangkang Keluli Karbon / Tiub SS316 | Tiub bersirip tekanan tinggi, air penyejuk 32°C |
| Paip Tekanan Tinggi | Keluli Tahan Karat yang Lancar | SS316, bebibir ANSI Kelas 900 |
Semua komponen galas tekanan direka bentuk dan dikilangkan mengikut ketat ASME BPVC Bahagian VIII Bahagian 1 atau piawaian GB 150 Cina. Setiap sambungan kimpalan menjalani pemeriksaan radiografi (RT) 100% mengikut Seksyen V ASME, Artikel 2, dan setiap bekas tekanan yang telah siap tertakluk kepada ujian tekanan hidrostatik pada 1.5 kali ganda tekanan kerja maksimum yang dibenarkan (MAWP) untuk tempoh penahanan minimum selama 30 minit. Sistem perpaipan tekanan tinggi diperbuat daripada SS316 yang lancar dengan sambungan bebibir ANSI Kelas 900 untuk memastikan integriti kedap bocor pada tekanan operasi 3.00 MPa.
Garis Panduan Pemasangan & Penyelenggaraan
Keperluan Asas & Struktur
The 3ZW-9.5/30 has a dry weight of 3.50 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the three-stage high-pressure operation, the three-row opposed-cylinder design achieves excellent force balance, permitting installation on a blok inersia konkrit bertetulang 6–8 tan. 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. The high-pressure discharge piping (3.00 MPa) requires special attention to support and anchoring to prevent vibration-induced fatigue and ensure personnel safety.
Reka Bentuk Sistem Air Penyejuk
Permintaan air penyejuk adalah lebih kurang 22 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies three cylinder jacket circuits and two intercoolers in a parallel/series hybrid arrangement optimized for thermal management. Given the extreme pressure ratio, both intercoolers are critical for preserving PTFE ring integrity 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 is strongly recommended.
Jadual Penyelenggaraan Pencegahan
| Selang masa | Item Perkhidmatan | Tindakan Diperlukan |
|---|---|---|
| Harian | Pemeriksaan Operasi | Check vibration, abnormal noise, cooling water flow, all stage discharge pressures and temperatures |
| 250 jam | Valve Plate Inspection (All Stages) | Remove and inspect all suction/discharge valves for carbon deposits, spring fatigue, cracking |
| 1,000 jam | Piston Ring Wear Assessment (All Stages) | Measure groove clearance on all stages; replace rings if clearance exceeds 0.18 mm |
| 3,000 jam | Baik Pulih Pertengahan | Replace all piston rings, rider bands, and valve plate assemblies on all three stages |
| 6,000 jam | Baik Pulih Utama | Inspect crankshaft journals, measure all bearing clearances, replace bearings if >0.08 mm |
The oil-free design of the 3ZW-9.5/30 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 Cincin omboh PTFE dan jalur penunggang, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions. The high-pressure valve plates in the third stage may require more frequent inspection (every 2,000 hours) due to the extreme mechanical stress at 3.00 MPa, but the overall maintenance burden remains significantly lower than oil-lubricated systems.
Pensijilan Pematuhan & Keselamatan
The 3ZW-9.5/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Bahagian VIII Div.1, GB 150-2011, PED 2014/68/EU Modul A
IEC 60034-1 (kecekapan IE3), IEC 60204-1, ISO 12100 keselamatan jentera
ISO 8573-1 Kelas 0 (Kandungan Minyak), diuji secara bebas oleh TÜV Rheinland
ISO 9001:2015, ISO 14001:2015
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-9.5/30 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. All high-pressure piping must be guarded or shielded to protect personnel from jetting in the event of rupture. 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 before operating or maintaining this equipment. Lock-out/tag-out procedures are mandatory for all maintenance activities.
Analisis Prestasi & Kecekapan
The 3ZW-9.5/30 achieves a specific power consumption of approximately 11.58 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression through three stages. Within the high-pressure oil-free 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, a diaphragm compressor delivering equivalent capacity and pressure would typically consume 16–20 kW/m³/min and cost 4–6 times more in capital expenditure.
Over an 8,000-hour annual operating schedule, the 3ZW-9.5/30’s efficiency advantage versus diaphragm alternatives yields approximately 340,000–530,000 kWh of annual energy savings. At $0.08/kWh, this represents $27,200–$42,400 in direct electricity cost reduction per year. However, the primary economic driver for 3ZW-9.5/30 selection is typically the combination of high capacity, moderate capital cost, and native oil-free operation that is unattainable with other compressor technologies at this pressure level. The jumlah kos pemilikan untuk pemampatan nitrogen tekanan ultra tinggi is reduced by an estimated 40–50% over a 10-year operational life when the three-stage piston design is compared to multi-diaphragm systems.
The three-stage design also provides superior pressure stability compared to single-stage high-pressure compressors, which is critical for process applications where pressure fluctuations could affect product quality or process safety. The inter-stage cooling ensures that each stage operates at optimal thermodynamic efficiency, minimizing the overall power consumption for the required pressure rise.
Keupayaan Penyesuaian & OEM
We offer comprehensive customization options to adapt the 3ZW-9.5/30 to specific site conditions, integration requirements, and end-user specifications:
- Pakej Siap Kunci yang Dipasang di Gelincir: Pre-assembled compressor, motor, three coolers, 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 60%.
- Konfigurasi Kawasan Berbahaya: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks with emergency isolation valves.
- Kawalan Proses Lanjutan: 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 sequencing and high-pressure safety interlocks including emergency blowdown.
- Perlindungan Alam Sekitar: Salutan gred marin C5-M untuk pemasangan pesisir; komponen elektrik tropika untuk suhu ambien 55°C; kandang akustik berkadar IP54 yang mengurangkan hingar daripada 85 dB(A) kepada 72 dB(A) pada 1 meter.
- Label OEM & Persendirian: Warna cat tersuai, papan nama berjenama dan dokumentasi setempat untuk pengedar peralatan gas dan penyepadu sistem.
Konfigurasi tersuai tersedia daripada MOQ 1 unit. Engineering proposals are typically delivered within 5–7 business days. Standard delivery time is 12–14 weeks; repeat orders are delivered in 8–10 weeks from order confirmation.
Case Study: Industrial Gas Cylinder Filling Station Upgrade
Pelanggan: A major industrial gas distributor in Indonesia serving manufacturing, healthcare, and electronics sectors
Cabaran: The client’s existing cylinder filling station used an oil-lubricated two-stage compressor feeding a diaphragm filling compressor. Oil contamination from the primary compressor was migrating through the system, causing the diaphragm compressor’s final purification beds to require replacement every 4 months instead of the designed 18-month interval. Oil levels in filled cylinders reached 2.0 mg/m³, exceeding the 0.1 mg/m³ specification for medical and electronics-grade nitrogen. The diaphragm compressor was also operating at reduced efficiency due to oil-fouled heat exchangers.
Penyelesaian: Kami membekalkan 3ZW-9.5/30 oil-free nitrogen compressor as the primary booster, replacing the oil-lubricated unit. The three-stage design provided a stable 3.00 MPa intermediate pressure that improved the downstream diaphragm compressor’s efficiency by 15%. The oil-free design eliminated the need for activated carbon purification beds entirely. The unit was configured on a custom skid with integrated coolers and a Siemens S7-1200 PLC with remote monitoring.
Keputusan yang Diukur Selepas 18 Bulan:
- Nitrogen oil content in filled cylinders: Reduced from 2.0 mg/m³ to <0.01 mg/m³, mencapai ISO 8573-1 Kelas 0
- Penggantian katil karbon teraktif: Dihapuskan sepenuhnya, menjimatkan $18,000/tahun dalam bahan habis pakai
- Diaphragm compressor efficiency: Improved by 15%, reducing its power consumption by 22 kW
- Customer complaints and returns: Sifar since commissioning, with contracts renewed for 3 additional years
- Tempoh bayaran balik: 2.3 tahun based on cost savings and contract renewals
“The 3ZW-9.5/30 has completely transformed our filling station. The oil-free design eliminated our quality control issues overnight, and the three-stage compression has made our downstream equipment run more efficiently than ever. Our medical gas customers have noticed the difference immediately.” — Operations Director, Industrial Gas Distributor
Soalan Lazim & Panduan Pemilihan
Produk & Penyelesaian Berkaitan
Pemampat Bebas Minyak Berbilang Peringkat Siri ZW
Pemampat bebas minyak berbilang peringkat menegak untuk oksigen, nitrogen, hidrogen dan gas khusus. Tekanan pelepasan sehingga 9.00 MPa untuk aplikasi pengisian gas tekanan ultra tinggi dan proses kimia.
Pemampat Nitrogen Tekanan Tinggi Siri DW
Direka untuk tekanan pelepasan dari 0.40 MPa hingga 2.00 MPa, siri DW merangkumi suntikan nitrogen, penggalakan saluran paip tekanan tinggi dan sintesis kimia. Kapasiti dari 2 hingga 130 m³/min.
Pemampat Nitrogen Berkapasiti Besar Siri LW
Pemampat omboh bebas minyak aliran tinggi (20–130 m³/min) untuk sandaran ASU kriogenik, penggalak VPSA dan pengagihan saluran paip perindustrian. Tekanan pelepasan dari 0.30 hingga 0.80 MPa.
Untuk gambaran keseluruhan yang komprehensif tentang kami pemampat nitrogen perindustrian portfolio, termasuk pemampat oksigen bebas minyak, pemampat hidrogen, pemampat karbon dioksida dan penyelesaian gas khusus yang direka khas, sila hubungi pasukan kejuruteraan aplikasi kami atau layari katalog produk dalam talian kami.
Bersedia untuk Menaik Taraf Sistem Nitrogen Tekanan Ultra Tinggi Anda?
Jurutera aplikasi kami sedia membantu untuk menilai keperluan aliran nitrogen, keadaan sedutan, sasaran tekanan pelepasan dan kekangan integrasi anda. Kami menyediakan cadangan teknikal percuma, lukisan susun atur asas, gambar rajah perpaipan dan instrumentasi (P&ID), serta analisis jumlah kos pemilikan (TCO) terperinci dalam tempoh 48 jam selepas menerima pertanyaan anda.
Emel: [email protected] | Respons dalam masa 24 jam
