ZW-13/30 stikstofcompressor – Olievrije N2-booster met gemiddelde capaciteit voor hogedrukprocesapplicaties van 3,00 MPa

De ZW-13/30 is een tweetraps, drierijige, olievrije zuigercompressor voor stikstof, ontworpen om 13 m³/min te leveren bij een persdruk van 3,00 MPa. Hij is geschikt voor veeleisende toepassingen zoals stikstofinjectie onder hoge druk, vulstations voor gasflessen en kritische petrochemische processen. De compressor is olievrij, heeft een robuuste krachtbalans over drie rijen en is geoptimaliseerd voor continu bedrijf bij verhoogde druk.

Productoverzicht

De ZW-13/30 nitrogen compressor represents a powerful mid-range solution within our oil-free piston compressor family, engineered for applications where both substantial flow capacity and high discharge pressure are simultaneously required. With a rated capacity of 13 m³/min en een afvoerdruk van 3,00 MPa, this unit occupies a critical position in the high-pressure nitrogen compressor market, bridging the gap between small laboratory-scale units and massive industrial boosters.

What distinguishes the ZW-13/30 from conventional alternatives is its volledig olievrij compressiepad utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, achieving ISO 8573-1 Klasse 0-certificering natively. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is substantially magnified compared to low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for food-grade, pharmaceutical, and electronics-grade nitrogen service.

De compressorarchitectuur maakt gebruik van een two-stage, three-row (二列三级) configuration that is essential for managing the extreme pressure ratio required to achieve 3.00 MPa from typical inlet conditions. The three-row opposed-cylinder arrangement provides superior force balance compared to two-row designs, reducing vibration transmission and permitting installation on lighter foundations. Each compression stage is equipped with an independent high-efficiency intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-load operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120.000 uur volgens standaard onderhoudsprotocollen.

Technical Specifications – ZW-13/30

* 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-Row Opposed-Cylinder Force Balance

The ZW-13/30 employs a unique three-row opposed-cylinder arrangement (二列三级) that provides exceptional first-order and second-order force cancellation. By distributing the compression work across three cylinders arranged in an opposed configuration, the compressor achieves near-perfect inertial force balance, reducing vibration transmission to the foundation by over 90% compared to single-row designs. 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 design permits installation on a lighter reinforced concrete inertia block (minimum 10 tonnes versus 15+ tonnes for equivalent single-row units), significantly reducing civil engineering costs and simplifying retrofit installations in existing process plants.

2. High-Pressure Oil-Free PTFE Composite Sealing

The ZW-13/30 utilizes a proprietary zelfsmurende zuigerveer- en geleidebandassemblage manufactured from high-density PTFE composites specifically formulated for high-pressure service. These rings are reinforced with glass fiber and bronze particulates 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 far more concentrated and difficult to remove. The ZW-13/30’s native oil-free design achieves ISO 8573-1 Klasse 0-certificering without any downstream filtration, eliminating both the capital cost and the energy penalty of oil-removal equipment. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity under the extreme thermal stress of high-pressure compression.

3. Two-Stage Thermodynamic Optimization for Extreme Pressure Ratios

De tweetraps compressiearchitectuur of the ZW-13/30 is thermodynamically essential for achieving the 3.00 MPa discharge pressure target from typical inlet pressures of 0.05–0.10 MPa. The overall pressure ratio of approximately 30:1 to 60:1 is divided between a low-pressure cylinder group and a high-pressure cylinder group, with each stage operating at a manageable pressure ratio. A high-efficiency shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 160°C and preventing thermal degradation of the PTFE sealing elements. Without staged compression, the discharge temperature would exceed 250°C, far beyond the safe operating limit of any oil-free sealing material. The inter-stage cooling is therefore not merely an efficiency enhancement but a fundamental requirement for reliable high-pressure oil-free operation.

4. Standard 380V Industrial Motor Drive with High Efficiency

The ZW-13/30 is driven by a 160 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 reduces both capital expenditure and commissioning complexity, making the unit accessible to a wide range of industrial facilities. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied on a common skid, providing seamless integration into any electrical infrastructure.

Toepassingsscenario's

Hogedrukstikstofcilindervulstations

The ZW-13/30 is ideally suited for industrial nitrogen cylinder filling operations where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa filling pressure. While the compressor’s 3.00 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. The 13 m³/min capacity can supply multiple filling manifolds simultaneously, making the ZW-13/30 suitable for commercial gas filling stations serving industrial, medical, and specialty gas markets. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users, potentially compromising their processes and creating liability exposure.

Petrochemical High-Pressure Process Nitrogen

In petrochemical and refinery operations, the ZW-13/30 high-pressure nitrogen compressor provides nitrogen for reactor catalyst preservation, emergency injection into high-pressure vessels, pipeline pressure testing, and hydrostatic testing of process equipment. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during startup, shutdown, and upset conditions. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround campaigns. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free.

Gas Liquefaction & Cryogenic Storage Booster

In nitrogen liquefaction plants and cryogenic storage facilities, the ZW-13/30 compresses nitrogen from the liquefier vaporizer or storage tank boil-off to the pressure required for distribution or further processing. The 3.00 MPa discharge pressure is sufficient for feeding high-pressure nitrogen into cryogenic storage systems, driving nitrogen through heat exchangers, and supplying high-pressure consumers in the process plant. The 13 m³/min capacity matches the output of small to medium-scale liquefaction plants, making the ZW-13/30 an ideal integrated booster for on-site nitrogen liquefaction systems. The oil-free design prevents contamination of the cryogenic equipment and ensures the purity of liquid nitrogen product.

Pharmaceutical & Food-Grade High-Pressure Nitrogen

Pharmaceutical manufacturing and large-scale food processing facilities require high-purity nitrogen at elevated pressure for sterile filtration, spray drying, aseptic filling, and high-pressure packaging applications. The ZW-13/30’s oil-free certification ensures compliance with FDA 21 CFR 211.72 and EU GMP Annex 1. The 3.00 MPa discharge pressure provides adequate head to drive nitrogen through sterile filtration systems, spray dryers, and high-pressure packaging equipment. The 13 m³/min capacity can simultaneously supply multiple pharmaceutical process lines or food packaging stations within a single manufacturing facility, making the ZW-13/30 a versatile central nitrogen supply solution.

Materiaal en constructie

The ZW-13/30 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal resistance, and extended operational life:

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 ZW-13/30 has a dry weight of 6.00 tonnes and a center of gravity approximately 900 mm above the baseplate. Thanks to the three-row opposed-cylinder design, unbalanced forces are minimal despite the high-pressure operation, permitting installation on a gewapend betonnen traagheidsblok van 10-12 ton. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz). Minimum clearance requirements: 1.5 m on the non-drive side for valve access, 1.2 m on the drive side for motor maintenance, and 2.0 m overhead for crane access during major overhauls. Special attention must be paid to the high-pressure discharge piping, which must be properly supported, anchored, and stress-relieved to prevent vibration-induced fatigue at 3.00 MPa.

Ontwerp van koelwatersystemen

De koelwaterbehoefte bedraagt ​​ongeveer 28 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches. Given the extreme pressure ratio, the intercooler is absolutely critical for thermal management and must receive priority 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.

Preventief onderhoudsschema

The oil-free design of the ZW-13/30 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 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. The high-pressure valve plates may require more frequent inspection than low-pressure equivalents due to the increased mechanical stress at 3.00 MPa, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

Certificeringen voor naleving en veiligheid

The ZW-13/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Prestatie- en efficiëntieanalyse

The ZW-13/30 achieves a specific power consumption of approximately 12.31 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, where the work required increases substantially with pressure ratio. Within the high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is competitive and often superior to diaphragm compressors, which are the primary alternative for oil-free 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 ZW-13/30’s efficiency advantage versus less efficient alternatives yields approximately 60,000–140,000 kWh of annual energy savings. At $0.08/kWh, this represents $4,800–$11,200 in direct electricity cost reduction per year. However, the primary economic driver for ZW-13/30 selection 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 3.00 MPa, the partial pressure of oil vapor is approximately 15 times higher than at 0.30 MPa, making downstream oil-filtration systems exponentially more expensive and less effective. The total cost of ownership for ultra-high-pressure nitrogen compression is reduced by an estimated 25–35% over a 10-year operational life when oil-free operation is compared to lubricated systems with full downstream purification.

The absence of oil in the compression path is particularly critical at 3.00 MPa because oil contamination becomes highly concentrated and virtually impossible to remove to the levels required by food-grade, pharmaceutical, and semiconductor applications. The ZW-13/30’s native oil-free design eliminates this challenge entirely, providing guaranteed product purity without the complexity and cost of downstream purification trains.

Mogelijkheden voor maatwerk en OEM-productie

We offer comprehensive customization options to adapt the ZW-13/30 to specific site conditions, integration requirements, and end-user specifications:

• Kant-en-klare pakketten op een frame: Pre-assembled compressor, motor, intercooler, 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 and risk.
• Configuraties van gevaarlijke zones: Motor- en elektrische behuizingen voor petrochemische installaties, conform ATEX Zone 2 en IECEx. Geïntegreerde gasdetectie en automatische ventilatievergrendelingen in het besturingssysteem.
• Geavanceerde procesbesturing: Optioneel: Siemens S7-1200 of Allen-Bradley CompactLogix PLC met 10-inch HMI-touchscreen, bewaking op afstand via Modbus TCP/IP of OPC-UA en naadloze DCS/SCADA-integratie. Veiligheidsvergrendelingen voor hoge druk, waaronder automatische ontlasting bij overdruk, noodafsluitkleppen en redundante drukbewaking.
• Milieubescherming: C5-M coatingsystemen van maritieme kwaliteit voor installaties aan de kust; tropische elektrische componenten voor omgevingstemperaturen tot 55 °C; en IP54-gecertificeerde geluidsisolerende behuizingen die de geluidsemissie reduceren van 85 dB(A) tot 72 dB(A) op 1 meter afstand.
• OEM & Private Label: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators. Technical manuals and maintenance procedures available in multiple languages.

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: Industrial Gas Filling Station Upgrade

Cliënt: A major industrial gas supplier in Malaysia operating a nitrogen cylinder filling station serving manufacturing, medical, and food processing customers

Uitdaging: The client’s existing oil-lubricated high-pressure compressor (European brand, 14 years in service) was experiencing progressive oil carryover into the nitrogen product stream. Oil contamination levels reached 2.2 mg/m³, far exceeding the 0.1 mg/m³ specification required by pharmaceutical and food-grade customers. The oil was also degrading the activated carbon purification beds in the filling manifold, requiring replacement every 5 months instead of the designed 18-month interval. Customer complaints were increasing, and regulatory inspections were becoming more frequent and demanding.

Oplossing: Wij leverden een ZW-13/30 oil-free nitrogen compressor as the primary intermediate booster, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel. The 3.00 MPa discharge pressure fed a downstream high-pressure filling compressor, reducing the overall compression ratio required of the filling stage. The oil-free design eliminated the need for activated carbon purification beds entirely. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from the filling manifold.

Gekwantificeerde resultaten na 24 maanden:

• Stikstofgehalte van de olie: Verlaagd van 2,2 mg/m³ naar <0,01 mg/m³, waarbij ISO 8573-1 Klasse 0 is behaald
• Activated carbon bed replacement: Volledig geëlimineerdwaardoor jaarlijks $12.000 aan verbruiksartikelen wordt bespaard.
• Customer complaints: Nul since commissioning, with five new pharmaceutical contracts won
• Filling compressor maintenance: Reduced by 35% due to lower inlet pressure ratio
• Regulatory inspection results: Passed with zero findings in two consecutive audits
• Terugverdienperiode: 2.3 years based on cost savings and new contract revenue

“The ZW-13/30 has transformed our filling station from a quality risk into a competitive advantage. We now guarantee ISO 8573-1 Class 0 nitrogen to every customer, and we’ve won contracts that we couldn’t even bid on before. The oil-free design has eliminated our biggest operational headache and our customers have noticed the difference immediately.” — Operations Director, Industrial Gas Supplier

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