Beschrijving
3ZW-6/30 stikstofcompressor – drietraps olievrije N2-booster voor hogedrukprocesapplicaties van 3,00 MPa
De 3ZW-6/30 is een drietraps, drierijige olievrije zuigercompressor voor stikstof, ontworpen om 6 m³/min te leveren bij een persdruk van 3,00 MPa. Hij is geschikt voor stikstofinjectie onder ultrahoge druk, vulstations voor gasflessen en veeleisende chemische syntheseprocessen. De compressor heeft geen olieverontreiniging, een robuuste meertrapsconstructie en is geoptimaliseerd voor continu gebruik onder extreme druk.
Productoverzicht
De 3ZW-6/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor technology, engineered specifically for applications that demand both substantial flow capacity and ultra-high discharge pressure. With a rated capacity of 6 m³/min en een uitzonderlijke 3,00 MPa uitlaatdruk, this unit occupies the high-pressure segment of our industrial nitrogen compressor portfolio, serving the most demanding process applications in the chemical, petrochemical, and gas distribution industries.
The “3ZW” designation signifies the three-stage, three-row (三列三级) architecture that is fundamental to achieving the 3.00 MPa discharge pressure while maintaining thermal stability and mechanical reliability. Each of the three compression stages operates at a moderate pressure ratio, with dedicated intercoolers between stages removing the heat of compression. This multi-staged approach is essential because the overall pressure ratio from atmospheric inlet to 3.00 MPa exceeds the safe operating limits of single-stage or two-stage designs, both in terms of discharge temperature and mechanical stress on the pistons and crankshaft.
What distinguishes the 3ZW-6/30 from conventional alternatives is its volledig olievrij compressiepad. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is exponentially higher than at low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for any application requiring high-purity nitrogen. The unit achieves ISO 8573-1 Klasse 0-certificering natively, without downstream oil-filtration equipment.
Technical Specifications – 3ZW-6/30
| Parameter | Waarde | Eenheid |
|---|---|---|
| Model | 3ZW-6/30 | – |
| Patroon | Three-stage, Three-row (三列三级) | – |
| Capaciteit | 6 | m³/min |
| Afvoerdruk | 3.00 | MPa |
| Compressorafmetingen (L × B × H) | 1845 × 1660 × 2360 | mm |
| Gewicht | 3.00 | T |
| Stroom | 75 | kW |
| Spanning | 380 | V |
| Gasmedium | Stikstof (N₂) | – |
| Smering | Olievrij | – |
* Alle specificaties zijn gebaseerd op standaard referentieomstandigheden (ISO 1217, bijlage C). De werkelijke prestaties kunnen variëren afhankelijk van de hoogte van de locatie, de omgevingstemperatuur en de inlaatcondities.
Belangrijkste kenmerken en technische voordelen
1. Three-Stage Compression for Ultra-High Pressure
De three-stage, three-row architecture of the 3ZW-6/30 is the engineering foundation that makes 3.00 MPa discharge pressure achievable with oil-free piston technology. The overall pressure ratio of approximately 30:1 to 60:1 (from atmospheric inlet) is divided across three compression cylinders, with each stage operating at a pressure ratio of approximately 3:1 to 4:1. This staged approach is thermodynamically essential because single-stage compression to 3.00 MPa would produce discharge temperatures exceeding 300°C, far beyond the safe operating limit of PTFE sealing materials. Between each stage, a dedicated high-efficiency shell-and-tube intercooler removes the heat of compression, maintaining discharge temperatures below 155°C at all stages. This thermal management preserves PTFE ring integrity and extends valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios.
2. Advanced High-Pressure Oil-Free PTFE Sealing System
The 3ZW-6/30 employs a proprietary zelfsmurende zuigerveer- en geleidebandassemblage manufactured from ultra-high-performance PTFE composites specifically formulated for 3.00 MPa service. These rings are reinforced with glass fiber, bronze particulates, and molybdenum disulfide to achieve a coefficient of friction below 0.05 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 severe and more difficult to remove downstream. The 3ZW-6/30’s native oil-free design achieves ISO 8573-1 Klasse 0-certificering without any downstream filtration, coalescing, or adsorption equipment. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, with a safety margin that accommodates transient temperature excursions during startup and load changes.
3. Three-Row Opposed-Cylinder Force Balance
Het hoofdframe is gegoten uit GG25 grijs gietijzer with reinforced wall sections and integral cooling water passages. The three-row opposed-cylinder arrangement provides superior force balance compared to single-row or two-row designs, with first-order and second-order inertial forces largely self-canceling. This mechanical advantage is particularly critical for high-pressure compressors where the peak gas forces on the pistons are substantially higher than in low-pressure applications. The three-row configuration reduces the unbalanced forces transmitted to the foundation by over 85% compared to single-row designs, permitting installation on a lighter reinforced concrete inertia block (minimum 5 tonnes) and reducing the risk of vibration-induced fatigue in connected piping systems. The compact dimensions—1845 × 1660 × 2360 mm—are remarkable for a three-stage compressor of this pressure class, achieved through a vertically stacked cylinder arrangement that minimizes the machine’s footprint.
4. Standaard 380V industriële motoraandrijving
The 3ZW-6/30 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 switchgear or step-down transformers. This electrical simplicity is particularly valuable for the 3ZW-6/30 because its moderate power requirement (75 kW) does not justify the complexity and cost of medium-voltage infrastructure. The motor is directly coupled to the crankshaft through a flexible disc coupling, eliminating the maintenance burden and efficiency losses associated with belt or gearbox drives.
Toepassingsscenario's
Ultra-High-Pressure Nitrogen Cylinder Filling
The 3ZW-6/30 is the ideal primary booster for nitrogen cylinder filling stations serving industrial, medical, and specialty gas markets. While the compressor’s 3.00 MPa discharge pressure does not reach the 15–20 MPa required for direct cylinder filling, it serves as a highly efficient intermediate stage that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. In a typical filling station configuration, the 3ZW-6/30 boosts nitrogen from 0.05–0.10 MPa to 3.00 MPa, after which a compact high-pressure diaphragm or piston compressor completes the filling to 20 MPa. This staged approach improves overall system efficiency by 25–35% compared to single-stage high-pressure compression from atmospheric inlet. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the filled cylinders and delivered to end-users, potentially compromising their processes and exposing the filling station to liability.
Chemical Synthesis & High-Pressure Reactor Inerting
In chemische procesinstallaties, de 3ZW-6/30 nitrogen compressor provides ultra-high-pressure nitrogen for high-pressure reactor inerting, catalyst bed preservation, and emergency depressurization of process vessels. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into reactors operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during all phases of operation. The three-stage compression ensures that the nitrogen remains thermally stable and free of oil contamination, which is critical in chemical synthesis where even trace contaminants can poison catalysts, initiate unwanted side reactions, or compromise product purity. The 6 m³/min capacity can serve multiple high-pressure reactors simultaneously through a centralized nitrogen header.
Gas Liquefaction & Cryogenic Storage Pressure Maintenance
In nitrogen liquefaction plants and cryogenic storage facilities, the 3ZW-6/30 serves as a high-pressure booster that compresses nitrogen vapor from storage tanks or recondensers to the pressure required for distribution or further processing. The 3.00 MPa discharge pressure is adequate for driving nitrogen through heat exchangers, recondensers, and distribution networks in small to medium liquefaction plants. The oil-free design is essential because any oil contamination in the high-pressure nitrogen would be carried into the cryogenic system, where it would freeze and block heat exchanger passages, causing operational failures and costly maintenance. The three-stage compression with intercooling ensures that the nitrogen remains at manageable temperatures throughout the compression process, preventing thermal damage to downstream cryogenic equipment.
Oil & Gas Well Nitrogen Injection
In oil and gas production operations, high-pressure nitrogen is injected into wells for enhanced oil recovery (EOR), well stimulation, and gas lift operations. The 3ZW-6/30’s 3.00 MPa discharge pressure is sufficient for many shallow to medium-depth well applications, where nitrogen is used to displace oil, reduce reservoir pressure, or lift production fluids to the surface. The oil-free design prevents hydrocarbon contamination of the reservoir, which could alter formation permeability and reduce oil recovery efficiency. The 6 m³/min capacity can support continuous nitrogen injection for extended well stimulation campaigns or intermittent gas lift operations for multiple wells.
Materiaal en constructie
The 3ZW-6/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, thermal resistance, and extended operational life:
| component | Materiaal | Specificatie |
|---|---|---|
| Cylinder Block (1st Stage) | Grijs gietijzer | GG25 / HT250, standaard wanddikte |
| Cylinder Block (2nd Stage) | Grijs gietijzer | GG25 / HT250, reinforced wall + ribbing |
| Cylinder Block (3rd Stage) | Grijs gietijzer | GG25 / HT250, heavy-duty reinforced wall |
| Krukas | Gesmeed gelegeerd staal | 42CrMo4, Q&T, ISO 1940 G2.5 dynamisch gebalanceerd |
| Zuigerveren | PTFE-Glass-Bronze-MoS₂ Composite | Ultra-high-pressure rated, self-lubricating, 185°C max |
| Rider Bands | PTFE-composiet | Zuigergeleiding, anti-slijtage, slijtagesnelheid <0,04 mm/1000 uur |
| Klepplaten | Roestvrij staal | SS316, high-pressure concentric ring design |
| Intercoolers (×2) | Behuizing van koolstofstaal / buizen van RVS 316 | ASME VIII Div.1, 1,5× hydrotest, 30 min vasthouden |
| Nakoeler | Behuizing van koolstofstaal / buizen van RVS 316 | High-pressure finned tube, 32°C cooling water |
| Hogedrukleidingen | Naadloos roestvrij staal | SS316, ANSI Klasse 900 flenzen |
Alle drukdragende componenten worden ontworpen en vervaardigd in strikte overeenstemming met ASME BPVC Sectie VIII Divisie 1 of de Chinese GB 150-normen. Elke lasverbinding ondergaat een 100% röntgeninspectie (RT) volgens ASME Sectie V, Artikel 2, en elk voltooid drukvat wordt onderworpen aan een hydrostatische druktest bij 1,5 keer de maximaal toelaatbare werkdruk (MAWP) gedurende een minimale wachttijd van 30 minuten. Hogedrukleidingsystemen worden vervaardigd van naadloos SS316 met ANSI Klasse 900 flensverbindingen om lekdichtheid te garanderen bij een werkdruk van 3,00 MPa.
Installatie- en onderhoudsrichtlijnen
Fundament- en constructie-eisen
The 3ZW-6/30 has a dry weight of 3.00 tonnes and a center of gravity approximately 800 mm above the baseplate. Thanks to the three-row opposed-cylinder design, unbalanced forces are minimal despite the ultra-high-pressure operation, permitting installation on a gewapend betonnen traagheidsblok van 5-6 ton. 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. Special attention must be paid to the high-pressure discharge piping, which must be properly supported with spring hangers and anchored to prevent vibration-induced fatigue at 3.00 MPa. All high-pressure connections must be verified with ultrasonic testing after installation.
Ontwerp van koelwatersystemen
De koelwaterbehoefte bedraagt ongeveer 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and two intercoolers in parallel branches. Given the three-stage compression and high pressure ratio, the intercoolers are absolutely critical for thermal management 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 and chemical treatment is strongly recommended for all installations to ensure consistent water quality and prevent scale formation in the intercoolers.
Preventief onderhoudsschema
| Interval | Serviceartikel | Actie vereist |
|---|---|---|
| Dagelijks | Operationele inspectie | Check vibration, abnormal noise, cooling water flow, discharge pressure/temperature at all stages |
| 250 uur | Valve Plate Inspection (All Stages) | Remove and inspect all suction/discharge valves for carbon deposits, spring fatigue, cracking |
| 1.000 uur | Piston Ring Wear Assessment (All Stages) | Measure groove clearance at all stages; replace rings if clearance exceeds 0.18 mm |
| 2,500 hours | Tussentijdse revisie | Replace all piston rings, rider bands, and valve plate assemblies across all three stages |
| 5,000 hours | Grote revisie | Inspect crankshaft journals, measure all bearing clearances, replace bearings if >0.06 mm |
The oil-free design of the 3ZW-6/30 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 PTFE-zuigerveren en geleidebanden, which typically achieve 2,500–4,000 hours of service life under clean nitrogen conditions at ultra-high pressure. The high-pressure valve plates (particularly on the third stage) may require more frequent inspection than low-pressure equivalents due to the increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems of equivalent pressure capability.
Certificeringen voor naleving en veiligheid
The 3ZW-6/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Sectie VIII Div.1, GB 150-2011, PED 2014/68/EU Module A
IEC 60034-1 (IE3-efficiëntie), IEC 60204-1, ISO 12100 machineveiligheid
ISO 8573-1 Klasse 0 (oliegehalte), onafhankelijk getest door TÜV Rheinland
ISO 9001:2015 (Kwaliteitsmanagement), ISO 14001:2015 (Milieumanagement)
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-6/30 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, with discharge directed to a safe location. All high-pressure piping must be designed, fabricated, and inspected in accordance with ASME B31.3 (Process Piping). 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 and wear appropriate PPE before operating or maintaining this equipment. No personnel shall be present in the compressor room during pressure testing or initial startup.
Prestatie- en efficiëntieanalyse
The 3ZW-6/30 achieves a specific power consumption of approximately 12.50 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure from atmospheric inlet. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the ultra-high-pressure oil-free piston 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, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 13.0–15.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.
Over a standard 8,000-hour annual operating schedule, the 3ZW-6/30’s efficiency advantage versus less efficient alternatives yields approximately 72,000–144,000 kWh of annual energy savings. At $0.08/kWh, this represents $5,760–$11,520 in direct electricity cost reduction per year. However, the primary economic justification for the 3ZW-6/30 is typically the het elimineren van oliegerelateerde verbruiksartikelen en het vermijden van apparatuur voor olieverwijdering verderop in het proces. that would be mandatory with lubricated alternatives at this pressure level. The total cost of ownership for ultra-high-pressure nitrogen compression De uitstoot wordt naar schatting met 30–45% verminderd gedurende een operationele levensduur van 10 jaar wanneer olievrije werking wordt vergeleken met gesmeerde systemen met volledige nazuivering.
The absence of oil in the compression path is particularly valuable at ultra-high pressure because oil contamination becomes exponentially more concentrated and more difficult to remove as pressure increases. At 3.00 MPa, the partial pressure of oil vapor would be approximately 15 times higher than at 0.30 MPa, making downstream oil-filtration systems virtually ineffective and prohibitively expensive. The 3ZW-6/30’s native oil-free design eliminates this challenge entirely, ensuring that nitrogen purity is maintained regardless of operating pressure.
Mogelijkheden voor maatwerk en OEM-productie
We offer comprehensive customization options to adapt the 3ZW-6/30 to specific site conditions, integration requirements, and end-user specifications:
- Kant-en-klare pakketten op een frame: Pre-assembled compressor, motor, three intercoolers, aftercooler, high-pressure discharge piping, 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 70%.
- Configuraties van gevaarlijke zones: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection, automatic ventilation interlocks, and explosion-proof instrumentation.
- Geavanceerde procesbesturing: 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-by-stage pressure monitoring and alarm systems. High-pressure safety interlocks including automatic unload on overpressure and emergency isolation valves on all stages.
- Milieubescherming: C5-M marine-grade coatings for coastal installations; tropicalized electrical components for 55°C ambient; IP54-rated acoustic enclosures reducing noise from 85 dB(A) to 72 dB(A) at 1 meter.
- OEM & Private Label: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators.
Aangepaste configuraties zijn beschikbaar via Minimale bestelhoeveelheid: 1 stukDe technische beoordeling en het opstellen van een voorstel duren doorgaans 5-7 werkdagen. De standaard levertijd is 12-14 weken; herhaalbestellingen worden binnen 8-10 weken na orderbevestiging geleverd.
Case Study: Chemical Synthesis Plant Nitrogen Injection Upgrade
Cliënt: A specialty chemical manufacturer in Indonesia operating high-pressure batch reactors for polymer production
Uitdaging: The plant required ultra-high-pressure nitrogen (2.80–3.00 MPa) for reactor inerting and catalyst bed preservation during batch polymerization cycles. Their existing oil-lubricated compressor (imported European brand, 12 years in service) was experiencing severe oil carryover into the nitrogen stream, with contamination levels reaching 5.2 mg/m³. This oil contamination was poisoning the Ziegler-Natta polymerization catalyst, reducing catalyst efficiency by 30% and causing off-specification polymer batches. The oil was also fouling the reactor heat transfer surfaces, requiring quarterly chemical cleaning. Annual maintenance costs had escalated to $65,000.
Oplossing: Wij leverden een 3ZW-6/30 oil-free nitrogen compressor as the primary high-pressure nitrogen source, configured on a custom skid with three integrated intercoolers, aftercooler, and a Siemens S7-1200 PLC control panel with stage-by-stage pressure monitoring. The 3.00 MPa discharge pressure met the reactor inerting requirements with a safety margin. The oil-free design eliminated catalyst poisoning and reactor fouling. A 2 m³ surge vessel was installed upstream to buffer demand fluctuations from the batch reactor cycle.
Gekwantificeerde resultaten na 18 maanden:
- Stikstofgehalte van de olie: Reduced from 5.2 mg/m³ to <0.01 mg/m³, waarbij ISO 8573-1 Klasse 0 is behaald
- Catalyst efficiency: Restored to 95% (from 65%), reducing catalyst consumption by 32%
- Off-specification batches: Volledig geëlimineerd, saving $45,000/year in rework costs
- Reactor cleaning frequency: Reduced from quarterly to annually, saving $18,000/year
- Jaarlijkse onderhoudskosten: Verminderd met 48% ($65,000 to $33,800)
- Terugverdienperiode: 1.6 years based on catalyst savings, rework elimination, and maintenance reduction
“The 3ZW-6/30 has transformed our polymerization process. The elimination of oil contamination has restored our catalyst performance to design levels and eliminated our off-spec batch problem. Our maintenance team now spends their time on preventive activities rather than emergency oil-related repairs. The payback was faster than our finance team projected.” — Production Director, Specialty Chemical Plant
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Ready to Upgrade Your Ultra-High-Pressure Nitrogen System?
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