Beskrivelse
ZW-3.1/5~20 Nitrogen Compressor – Variable-Pressure Oil-Free N2 Booster for Flexible Industrial Applications
Engineered to deliver 3.1 m³/min across a wide pressure range of 0.50–2.00 MPa, the ZW-3.1/5~20 is a two-stage, two-row oil-free piston nitrogen compressor designed for pilot plants, R&D facilities, and small-scale industrial processes requiring adjustable discharge pressure. Zero lubricant contamination, compact footprint, and optimized for versatile nitrogen supply.
Produktoversikt
The ZW-3.1/5~20 nitrogen compressor represents a uniquely versatile solution within our oil-free piston compressor family, distinguished by its variable discharge pressure capability spanning 0.50 MPa to 2.00 MPa. This pressure flexibility makes the ZW-3.1/5~20 ideally suited for pilot plant operations, research and development facilities, and small-scale industrial processes where nitrogen demand characteristics change frequently or where a single compressor must serve multiple applications with differing pressure requirements.
With a rated capacity of 3.1 m³/min at 0.50 MPa inlet pressure, this compact unit delivers oil-free nitrogen compression through a proprietary self-lubricating PTFE composite piston ring and rider band system. The absence of hydrocarbon lubricants in the compression path ensures ISO 8573-1 Class 0 oil content certification natively, making the unit immediately suitable for laboratory-grade nitrogen, pharmaceutical process development, and electronics prototyping without additional downstream purification equipment.
The compressor follows a two-stage, two-row (二列二级) configuration with an exceptionally compact footprint of 2250 × 1296 × 2200 mm and a dry weight of only 2.60 tonnes. The two-row opposed-cylinder design inherently cancels first-order inertial forces, permitting installation on a modest foundation without specialized vibration isolation infrastructure. The standard 380V, 75 kW motor integrates directly into existing low-voltage industrial distribution systems, eliminating the need for medium-voltage switchgear.
Technical Specifications – ZW-3.1/5~20
| Parameter | Value | Unit |
|---|---|---|
| Modell | ZW-3.1/5~20 | – |
| Mønster | Two-stage, Two-row (二列二级) | – |
| Kapasitet | 3.1 (at 0.50 MPa inlet) | m³/min |
| Discharge Pressure Range | 0.50 – 2.00 | MPa |
| Compressor Size (L × W × H) | 2250 × 1296 × 2200 | mm |
| Vekt | 2.60 | t |
| Makt | 75 | kW |
| Spenning | 380 | V |
| Gassmedium | Nitrogen (N₂) | – |
| Lubrication | Oil-free | – |
* Capacity is rated at 0.50 MPa inlet pressure. Actual capacity varies with inlet pressure and discharge pressure settings. All specifications are rated at standard reference conditions (ISO 1217, Annex C). Actual performance may vary based on site altitude, ambient temperature, and operating conditions.
Key Features & Engineering Advantages
1. Variable Discharge Pressure for Multi-Application Flexibility
The defining characteristic of the ZW-3.1/5~20 is its adjustable discharge pressure range from 0.50 MPa to 2.00 MPa. This versatility is achieved through a combination of adjustable suction valve unloaders, variable clearance pocket control, and a robust two-stage compression architecture that can accommodate a wide range of pressure ratios. For pilot plant operators and R&D facilities, this means a single compressor can serve multiple process requirements—low-pressure inerting at 0.50 MPa during one campaign, medium-pressure reactor blanketing at 1.20 MPa during another, and high-pressure gas transfer at 2.00 MPa during a third—without requiring separate compressor investments or time-consuming equipment changeovers.
2. Oil-Free PTFE Composite Sealing Technology
The ZW-3.1/5~20 employs a proprietary self-lubricating piston ring and rider band assembly manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. These rings operate with a coefficient of friction below 0.08 without any external hydrocarbon lubrication, delivering ISO 8573-1 Class 0 oil content in the compressed nitrogen stream. For research laboratories, pharmaceutical pilot plants, and electronics development facilities, this native oil-free certification eliminates the need for downstream oil-filtration equipment, reducing both capital expenditure and ongoing maintenance complexity. The PTFE formulation is specifically engineered for the variable thermal conditions associated with adjustable pressure operation.
3. Compact Two-Stage Architecture with Intercooling
The two-stage, two-row compression layout 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 is particularly critical for the ZW-3.1/5~20 given its wide pressure range, as it limits the maximum discharge temperature per stage even at the highest pressure setting (2.00 MPa). The intercooler maintains gas temperatures below 160°C across the full operating envelope, preserving PTFE ring integrity and extending valve plate service life. The two-row opposed-cylinder arrangement also provides inherent first-order force balance, reducing vibration transmission and permitting installation on a lighter foundation.
4. Standard 380V Direct Drive for Easy Integration
The ZW-3.1/5~20 is driven by a 75 kW, 380V, 50Hz three-phase induction motor 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 infrastructure, step-down transformers, or specialized switchgear. This electrical simplicity is particularly advantageous for pilot plants and R&D facilities that may lack medium-voltage electrical infrastructure. The modest 75 kW power draw also minimizes demand charges and simplifies electrical permitting in facilities with limited power capacity.
Application Scenarios
Pilot Plant & Process Development
Chemical and pharmaceutical pilot plants frequently require nitrogen at varying pressures depending on the process campaign. The ZW-3.1/5~20 variable-pressure nitrogen compressor can supply low-pressure inerting (0.50–0.80 MPa) for reactor filling and emptying operations, medium-pressure blanketing (1.00–1.50 MPa) for stirred-tank reactors, and high-pressure gas transfer (1.80–2.00 MPa) for catalyst loading and filter press operations. This multi-pressure capability eliminates the need for multiple compressors or pressure-reducing stations, reducing both capital investment and plant footprint.
Research & Development Laboratories
University research laboratories, government research institutes, and corporate R&D centers require versatile nitrogen supplies for diverse experimental programs. The ZW-3.1/5~20 can provide low-pressure nitrogen (0.50 MPa) for glove box inerting and Schlenk line operations, medium-pressure nitrogen (1.00–1.50 MPa) for high-pressure reaction vessels and autoclaves, and high-pressure nitrogen (2.00 MPa) for gas chromatography carrier gas and mass spectrometry ionization sources. The oil-free certification ensures that nitrogen purity meets the stringent requirements of analytical instrumentation without additional purification.
Small-Scale VPSA Nitrogen Boosting
Small VPSA nitrogen generators (5–15 Nm³/h capacity) produce nitrogen at near-atmospheric pressure. The ZW-3.1/5~20 boosts this low-pressure product to the pressure required by the specific application, with the flexibility to adjust output pressure as demand changes. This is particularly valuable for facilities that serve multiple nitrogen consumers with different pressure requirements, such as a combination of low-pressure storage tank blanketing and high-pressure process vessel inerting.
Electronics Prototyping & Semiconductor Development
Electronics prototyping facilities and semiconductor development labs require nitrogen for reflow oven atmosphere control, wire bonding inerting, and component storage dry cabinets. The ZW-3.1/5~20’s variable pressure capability allows it to serve both low-pressure reflow ovens (0.50–0.80 MPa) and high-pressure wire bonding equipment (1.50–2.00 MPa) from a single source. The oil-free design is absolutely critical in electronics applications because even trace oil contamination can cause solder joint defects, conformal coating adhesion failures, and contamination of sensitive optical and MEMS components.
Material & Construction
The ZW-3.1/5~20 is constructed from materials selected for nitrogen compatibility, variable-pressure service, and long-term reliability:
| Component | Material | Specification |
|---|---|---|
| Cylinder Block | Gray Cast Iron | GG25 / HT250, integral cooling passages |
| Crankshaft | Forged Alloy Steel | 42CrMo4, Q&T, dynamically balanced |
| Piston Rings | PTFE-Glass-Bronze Composite | Self-lubricating, variable-pressure rated |
| Rider Bands | PTFE Composite | Piston guidance, anti-scuffing |
| Valve Plates | Stainless Steel | SS316, concentric ring spring-loaded |
| Intercooler | Carbon Steel Shell / SS304 Tubes | ASME VIII Div.1, 1.5× hydrotest |
| Aftercooler | Carbon Steel Shell / SS304 Tubes | Finned tube, 32°C cooling water rated |
| Base Frame | Structural Steel | Welded, vibration-damped mounting |
All pressure-bearing components conform to ASME BPVC Section VIII Division 1 or Chinese GB 150 standards. Weld joints undergo 100% radiographic inspection (RT), and each pressure vessel is hydrostatically tested at 1.5× MAWP for a minimum 30-minute hold period.
Installation & Maintenance Guidelines
Foundation & Spatial Requirements
The ZW-3.1/5~20 weighs 2.60 tonnes and features a compact vertical design with a low center of gravity. A reinforced concrete pad of 4–5 tonnes is sufficient for stable operation, mounted on standard elastomeric vibration isolators (natural frequency 8–12 Hz). The two-row opposed-cylinder arrangement inherently cancels first-order inertial forces, minimizing vibration transmission. Required clearances: 1.0 m on the non-drive side for valve access, 0.8 m on the drive side for motor maintenance, and 1.5 m overhead for routine service. The compact footprint allows installation in existing machinery rooms, containerized units, or mobile skids.
Cooling Water Specifications
Cooling water demand is approximately 15 m³/h at an inlet temperature not exceeding 32°C. The water circuit supplies the cylinder jackets and intercooler in parallel. 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, a compact closed-loop cooling tower with a 0.5 m³ buffer tank is recommended.
Maintenance Intervals
| Interval | Service Item | Action Required |
|---|---|---|
| Daily | Visual & Operational Check | Inspect for leaks, abnormal noise, cooling water flow |
| 250 hours | Valve Plate Inspection | Check for carbon deposits, spring fatigue, or cracking |
| 1,000 hours | Piston Ring Wear Assessment | Measure groove clearance; replace if > 0.20 mm |
| 4,000 hours | Intermediate Service | Replace piston rings, rider bands, and valve assemblies |
| 8,000 hours | Major Overhaul | Inspect crankshaft, measure bearing clearances |
The oil-free design eliminates oil changes, filter replacements, and separator maintenance. The only consumable wear items are the PTFE piston rings and rider bands, typically achieving 4,000–6,000 hours under clean nitrogen conditions.
Compliance & Safety Certifications
The ZW-3.1/5~20 meets the following international standards:
ASME BPVC Section VIII Div.1, GB 150-2011, PED 2014/68/EU Module 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 asphyxiant gas. All installations must include continuous oxygen monitoring in the compressor room. Ventilation must maintain oxygen above 19.5% per OSHA 29 CFR 1910.146. Alarm at 19.5% O₂, hard shutdown at 18.0% O₂. Personnel entry requires portable O₂ monitors and buddy system.
Performance & Efficiency Analysis
The ZW-3.1/5~20 achieves a specific power consumption that varies with discharge pressure setting, ranging from approximately 24.2 kW/m³/min at 0.50 MPa til 24.2 kW/m³/min at 2.00 MPa (based on 75 kW power draw and 3.1 m³/min capacity). While the specific power is higher than larger compressors due to reduced scale efficiency, the ZW-3.1/5~20’s primary value proposition is its versatility—the ability to replace multiple single-pressure compressors with one adjustable unit.
For facilities that would otherwise require separate compressors for low-pressure (0.50 MPa), medium-pressure (1.20 MPa), and high-pressure (2.00 MPa) service, the ZW-3.1/5~20 eliminates the capital cost of two additional compressors, the associated piping and instrumentation, and the floor space they would occupy. The total cost of ownership for flexible nitrogen compression is often lower than maintaining multiple single-purpose compressors, even when accounting for the slightly higher specific power consumption.
Customization & OEM Capabilities
We provide flexible customization for the ZW-3.1/5~20:
- Skid-Mounted Packages: Pre-assembled compressor, motor, cooler, and controls on a structural steel skid with forklift pockets. Reduces field installation to electrical and cooling water connections only.
- Mobile Trailer Units: Mounted on a road-legal trailer with integrated diesel generator and cooling system for fully mobile nitrogen supply at construction sites and remote locations.
- PLC & Remote Monitoring: Optional Siemens LOGO! or S7-1200 PLC with HMI touchscreen, Ethernet connectivity, and SMS/email alarms. Modbus TCP/IP compatible for SCADA integration.
- Acoustic Enclosures: Compact IP54-rated enclosure reducing noise from 82 dB(A) to 68 dB(A) at 1 meter, suitable for laboratory and office-adjacent installations.
- OEM & Private Label: Custom paint, branded nameplates, and localized documentation for distributors and system integrators.
Custom configurations available from MOQ 1 unit. Engineering proposals within 3–5 business days. Standard delivery 10–12 weeks; expedited 8 weeks available.
Case Study: Pharmaceutical Pilot Plant Nitrogen Supply
Client: A pharmaceutical development company in Singapore
Challenge: The pilot plant operated three separate nitrogen compressors: a 0.50 MPa unit for reactor inerting, a 1.20 MPa unit for filter press operations, and a 2.00 MPa unit for catalyst loading. The three compressors occupied excessive floor space, required separate maintenance schedules, and had a combined annual maintenance cost of $32,000. Oil contamination from one of the lubricated compressors had compromised a batch of active pharmaceutical ingredient (API), resulting in a $150,000 loss.
Solution: We supplied a ZW-3.1/5~20 oil-free variable-pressure nitrogen compressor on a compact skid with integrated controls. The unit replaced all three existing compressors, freeing 12 m² of floor space and eliminating oil contamination risk entirely. Pressure adjustment is performed via the HMI panel, allowing operators to select the required pressure for each process campaign.
Results After 18 Months:
- Floor space: Freed 12 m² by consolidating three compressors into one
- Annual maintenance cost: Reduced by 55% ($32,000 to $14,400)
- Oil contamination incidents: Zero since commissioning
- Process flexibility: Pressure changes completed in under 5 minutes via HMI, versus 2-hour compressor swapovers previously
- Payback period: 1.8 years based on maintenance savings and avoided contamination losses
“The ZW-3.1/5~20 has simplified our nitrogen supply dramatically. One compressor does the work of three, and we never have to worry about oil contamination compromising our API batches. The ability to change pressure from the control panel is a game-changer for our pilot plant operations.” — Process Engineering Manager
FAQ & Selection Guide
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For a complete overview of our industrial nitrogen compressor portfolio, contact our engineering team or browse our online catalog.
Need a Flexible Nitrogen Compression Solution?
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