ZW-4/8 stikstofcompressor – nauwkeurige olievrije N2-booster voor kleinschalige hogedruktoepassingen

Met een capaciteit van 4 m³/min bij een persdruk van 0,80 MPa is de ZW-4/8 een tweetraps, tweerijige olievrije zuigercompressor voor stikstof, ontworpen voor hogedruktoepassingen in laboratoria, inertisering van precisie-instrumenten en compacte industriële stikstofboosters waar verhoogde druk en absolute zuiverheid essentieel zijn.

Productoverzicht

De ZW-4/8 nitrogen compressor is a precision-engineered oil-free piston compressor designed for applications where high discharge pressure and compact footprint must coexist. With a rated capacity of 4 m³/min and an elevated discharge pressure of 0,80 MPa, this unit addresses the demanding requirements of high-pressure nitrogen distribution in laboratory complexes, precision manufacturing facilities, and small-scale industrial processes.

Unlike conventional compressors that compromise on either pressure capability or purity, the ZW-4/8 achieves both through a fully oil-free compression mechanism. The piston rings and rider bands are manufactured from advanced self-lubricating PTFE composites that operate without hydrocarbon lubricants, ensuring the nitrogen stream remains completely free of oil contamination. This native oil-free characteristic is essential for applications such as GC-MS carrier gas supply, pharmaceutical sterile processing, and semiconductor wafer handling where even trace oil vapor can compromise product integrity.

De tweetraps, twee rijen (二列二级) architecture is specifically optimized for the 0.80 MPa discharge pressure target. By distributing the pressure ratio across two compression stages with inter-stage cooling, the ZW-4/8 maintains discharge temperatures within safe limits while achieving the higher pressure output that single-stage designs cannot reach. The compact dimensions of 2250 × 1296 × 2200 mm and a weight of just 2.00 tonnes make this unit suitable for installation in confined machinery rooms, mobile skids, and containerized nitrogen supply systems.

Technical Specifications – ZW-4/8

* 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. High-Pressure Oil-Free Piston Technology

The ZW-4/8 employs a zelfsmurende zuigerveer- en geleidebandassemblage fabricated from high-density PTFE composites reinforced with glass fiber and bronze particulates. These rings achieve a coefficient of friction below 0.08 without any external lubrication, delivering ISO 8573-1 Klasse 0 oliegehalte certification in the compressed nitrogen stream. This is particularly critical for high-pressure applications where oil contamination would be amplified by the pressure ratio, making downstream oil removal exponentially more difficult and expensive.

2. Two-Stage Compression for Elevated Pressure Ratios

De tweefasige, tweerijige architectuur is thermodynamically essential for achieving the 0.80 MPa discharge pressure from typical nitrogen generator outlet pressures of 0.05–0.10 MPa. The first-stage cylinder compresses the nitrogen to an intermediate pressure of approximately 0.25–0.30 MPa, after which an inter-stage cooler removes the heat of compression. The second-stage cylinder then raises the pressure to the final 0.80 MPa target. This staged approach limits the discharge temperature of each stage to below 160°C, preventing thermal degradation of the PTFE sealing elements and maintaining valve plate integrity under the elevated pressure duty.

3. Compact Footprint with High Power Density

Bij 2250 × 1296 × 2200 mm, the ZW-4/8 occupies less than 3 m² of floor space while delivering 0.80 MPa discharge pressure—a combination that is difficult to achieve with alternative compressor technologies. The compact vertical crankcase design minimizes the longitudinal footprint while providing adequate access for routine maintenance. The 2.00-tonne weight permits transportation and positioning using standard forklift equipment, making the ZW-4/8 suitable for retrofit installations in existing machinery rooms, mobile nitrogen supply skids, and containerized process units.

4. Efficient 380V Motor Drive

The ZW-4/8 is driven by a 30 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 IE3 efficiency class. The standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring specialized medium-voltage infrastructure. This electrical simplicity is particularly valuable for small-scale facilities, laboratories, and mobile installations where medium-voltage switchgear would be prohibitively expensive. The 30 kW power rating provides an excellent balance between compression capability and electrical demand, keeping operating costs manageable for intermittent-duty applications.

Toepassingsscenario's

High-Pressure Laboratory Nitrogen Supply

Research laboratories and analytical facilities require high-pressure nitrogen for gas chromatography carrier gas, mass spectrometry nebulizer gas, and inert atmosphere glove box supply. The ZW-4/8’s 0,80 MPa uitlaatdruk is sufficient to feed high-pressure nitrogen regulators and distribution manifolds serving multiple instruments simultaneously. The oil-free certification ensures that the nitrogen stream meets the stringent purity requirements of analytical instruments without requiring additional purification cartridges or oil-monitoring instrumentation. The 4 m³/min capacity can comfortably support 8–12 GC-MS systems or 4–6 ICP-MS instruments operating in parallel.

Precision Manufacturing & Semiconductor Inerting

In electronics and semiconductor manufacturing, nitrogen is used for wafer handling inerting, reflow oven atmosphere control, and component storage dry cabinets. The ZW-4/8 high-pressure nitrogen compressor delivers the 0.80 MPa pressure required for precision pressure regulators that maintain sub-atmosphere inert environments in glove boxes and wafer transfer chambers. The oil-free design is absolutely critical in these applications because even nanogram-level oil contamination can cause solder joint defects, conformal coating adhesion failures, and contamination of optical surfaces on precision components.

Pharmaceutical Sterile Processing & Aseptic Filling

Pharmaceutical manufacturing facilities use high-pressure nitrogen for aseptic filling line inerting, vial headspace displacement, and freeze-dryer chamber purging. The ZW-4/8’s 0.80 MPa discharge pressure provides the head necessary to feed nitrogen through HEPA-filtered distribution systems and precision pressure regulators that maintain sterile barrier pressures in isolators and restricted access barrier systems (RABS). The oil-free certification ensures compliance with FDA 21 CFR 211.72 (equipment construction) and EU GMP Annex 1 (sterile medicinal products) without requiring additional oil-removal validation.

Small-Scale VPSA Nitrogen Booster

For compact VPSA nitrogen generators producing 99.5–99.9% purity nitrogen at near-atmospheric pressure, the ZW-4/8 compresses the low-pressure product to 0.80 MPa for high-pressure distribution. The compact footprint allows the compressor to be mounted on the same skid as the VPSA generator, creating an integrated nitrogen supply system that occupies minimal floor space. The oil-free compression path protects the carbon molecular sieve from hydrocarbon poisoning, preserving the generator’s separation efficiency and extending adsorbent life by preventing irreversible contamination.

Materiaal en constructie

The ZW-4/8 is constructed from materials selected for high-pressure nitrogen compatibility, corrosion resistance, and long-term mechanical reliability:

Alle drukdragende componenten zijn ontworpen en vervaardigd in overeenstemming met ASME BPVC Sectie VIII Divisie 1 or Chinese GB 150 standards. Weld joints undergo 100% radiographic inspection (RT), and each pressure vessel is subjected to hydrostatic testing at 1.5× the maximum allowable working pressure (MAWP) for a minimum hold time of 30 minutes.

Installatie- en onderhoudsrichtlijnen

Fundament- en ruimtelijke vereisten

The ZW-4/8 weighs 2.00 tonnes and features a low center of gravity due to its compact vertical design. A reinforced concrete pad of 3–4 tonnes is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The two-row opposed-cylinder arrangement inherently cancels first-order inertial forces, minimizing vibration transmission to sensitive laboratory equipment or precision manufacturing machinery nearby. 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.

Specificaties koelwater

De koelwaterbehoefte bedraagt ​​ongeveer 8 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Acceptable water quality: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride < 50 mg/L, suspended solids < 30 mg/L. For laboratory installations without dedicated cooling water infrastructure, a compact air-cooled aftercooler option is available, eliminating the need for water supply entirely.

Preventief onderhoudsschema

The oil-free design of the ZW-4/8 dramatically reduces maintenance complexity compared to lubricated alternatives. There are no oil changes to schedule, no oil samples to analyze, no filter elements to replace, and no oil separator cartridges to monitor. The only consumable wear items are the PTFE-zuigerveren en geleidebanden, which typically achieve 4,000–6,000 hours of service under clean nitrogen conditions.

Certificeringen voor naleving en veiligheid

The ZW-4/8 nitrogen compressor meets or exceeds the following international standards and regulatory requirements:

Prestatie- en efficiëntieanalyse

The ZW-4/8 achieves a specifiek energieverbruik van circa 7,50 kW per m³/min of nitrogen at 0.80 MPa discharge pressure. While this specific power is higher than our larger LW-series models due to the reduced scale efficiency inherent in small-capacity compressors, it remains competitive within the sub-5 m³/min high-pressure oil-free piston segment. For comparison, oil-lubricated screw compressors in this pressure and size range typically consume 8.0–9.5 kW/m³/min, and diaphragm compressors (often selected for oil-free high-pressure duty) can exceed 12 kW/m³/min.

Over an 8,000-hour annual operating cycle, the ZW-4/8’s efficiency advantage versus less efficient alternatives yields approximately 12,000–32,000 kWh of energy savings per year. At $0.08/kWh, this represents $960–$2,560 in annual electricity cost reduction. However, the primary economic driver for ZW-4/8 selection is typically the eliminatie van oliegerelateerde verbruiksartikelen en apparatuur voor verdere zuivering in plaats van marginale energiebesparingen.

De total cost of ownership for high-pressure nitrogen compression in small-scale applications is dominated by maintenance labor and consumables. The ZW-4/8’s oil-free design eliminates oil changes ($300–600/year), filter replacements ($150–300/year), separator cartridge changes ($400–800/year), and oil analysis ($100–200/year), delivering total consumable savings of $950–$1,900 annually compared to lubricated alternatives. Additionally, the elimination of downstream oil-removal equipment (coalescing filters, activated carbon adsorbers, oil monitors) saves $3,000–$8,000 in capital expenditure.

Mogelijkheden voor maatwerk en OEM-productie

We provide flexible customization options to adapt the ZW-4/8 to specific installation constraints and end-user requirements:

• Pakketten op een frame: Voorgemonteerde compressor, motor, koeler en bedieningspaneel op een stalen frame met vorkheftruckopeningen en hijsogen. Vereenvoudigt de installatie ter plaatse tot alleen de elektrische aansluiting en de koelwateraansluiting.
• Mobiele aanhangwagens: The ZW-4/8 can be mounted on a road-legal trailer with integrated diesel generator, cooling system, and nitrogen storage, creating a fully mobile high-pressure nitrogen supply unit for construction sites, pipeline maintenance, and emergency response.
• Air-Cooled Configuration: Optional air-cooled aftercooler eliminates the need for cooling water supply, making the ZW-4/8 suitable for laboratory installations without plumbing infrastructure or mobile applications where water availability is limited.
• PLC en bewaking op afstand: Optional Siemens LOGO! or S7-1200 PLC with 7-inch HMI touchscreen, Ethernet connectivity, and SMS/email alarm notifications. Compatible with Modbus TCP/IP for SCADA integration.
• Akoestische behuizingen: Compact IP54-rated sound enclosure reducing noise from 82 dB(A) to 66 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments such as laboratories and office-adjacent machinery rooms.
• OEM & Private Label: Aangepaste lakafwerkingen, merknaamplaatjes en lokale documentatiepakketten voor distributeurs en systeemintegratoren van gasapparatuur.

Aangepaste configuraties zijn beschikbaar via Minimale bestelhoeveelheid: 1 stuk. Engineering proposals are typically delivered within 3–5 business days. Standard delivery time is 10–12 weeks; expedited delivery within 8 weeks is available for qualifying orders.

Case Study: Pharmaceutical Aseptic Filling Line Nitrogen Upgrade

Cliënt: A pharmaceutical manufacturing facility in Thailand specializing in sterile injectable products

Uitdaging: The facility was using a lubricated reciprocating nitrogen compressor to supply high-pressure nitrogen (0.70 MPa) to their aseptic filling lines. Oil contamination in the nitrogen stream was detected at 1.5 mg/m³, exceeding the 0.1 mg/m³ limit specified in their product quality agreement with international buyers. The oil was also causing frequent clogging of the 0.22 μm absolute filters in the nitrogen distribution system, requiring filter replacement every 3 weeks instead of the designed 6-month interval.

Oplossing: Wij leverden een ZW-4/8 oil-free nitrogen compressor as a direct replacement, configured on a custom skid with an air-cooled aftercooler (eliminating cooling water requirements), a Siemens LOGO! PLC control panel, and an integrated 0.5 m³ surge vessel. The skid footprint was designed to fit into the existing compressor room without civil modifications. The 0.80 MPa discharge pressure provided a safety margin above the 0.70 MPa required by the filling line regulators.

Resultaten na 24 maanden:

• Stikstofgehalte van de olie: Verlaagd van 1,5 mg/m³ naar <0,01 mg/m³, waarbij de ISO 8573-1 Klasse 0-certificering is behaald.
• Absolute filter replacement interval: Extended from 3 weeks to 8 months, saving $18,000/year in filter costs and reducing production downtime
• Totale onderhoudskosten: Decreased by 45% door het vervallen van olieverversingen, filtervervangingen en revisies van de separator.
• Product quality complaints: Zero oil-related rejections since commissioning, preserving international buyer contracts
• Ongeplande downtime: Nul gebeurtenissen in 24 maanden ononderbroken bedrijf

“The ZW-4/8 compressor solved our oil contamination problem permanently. Our filter replacement costs dropped by 85%, and we have not had a single quality rejection related to nitrogen purity since installation. The air-cooled option was a bonus—no cooling water meant one less utility to worry about.” — Quality Assurance Manager, Pharmaceutical Manufacturing Facility

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Ready to Upgrade Your High-Pressure Nitrogen Supply?

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