ZW-5.3/16 Stikstofcompressor – Olievrije hogedruk N2-booster voor industriële toepassingen tot 1,60 MPa

De ZW-5.3/16 is een tweetraps, drierijige olievrije zuigercompressor voor stikstof, ontworpen om 5,3 m³/min te leveren bij een persdruk van 1,60 MPa. Hij is speciaal ontwikkeld voor hogedrukstikstofinjectie, het vullen van cilinders en veeleisende petrochemische procesapplicaties. Geen olieverontreiniging, compact formaat en geoptimaliseerd voor continu bedrijf bij verhoogde druk.

Productoverzicht

De ZW-5.3/16 nitrogen compressor represents a specialized high-pressure solution within our oil-free piston compressor family, engineered for applications where elevated discharge pressure is the primary operational requirement. With a rated capacity of 5.3 m³/min en een uitzonderlijke 1.60 MPa discharge pressure, this unit occupies a unique position in the industrial nitrogen compression landscape—bridging the gap between conventional low-pressure boosters and ultra-high-pressure gas filling systems.

What distinguishes the ZW-5.3/16 from conventional alternatives is its fully oil-free compression mechanism utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, making the unit immediately suitable for high-purity nitrogen cylinder filling, pharmaceutical-grade nitrogen injection, and electronics process gas supply without additional downstream purification equipment. The oil-free certification is particularly critical at 1.60 MPa because oil contamination at elevated pressure becomes more difficult and costly to remove.

Zijn two-stage, three-row (二列三级) configuration delivers the high pressure ratio required for 1.60 MPa discharge while managing thermal loads through staged intercooling. The compact dimensions—1947 × 1900 × 2580 mm—allow the ZW-5.3/16 to fit into existing machinery rooms or containerized installations where floor space is at a premium. At 3.97 tonnes, the unit can be transported and positioned using standard forklift equipment.

Technical Specifications – ZW-5.3/16

* 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 PTFE Sealing Technology

The ZW-5.3/16 employs a proprietary zelfsmurend zuigerveer- en geleidebandsysteem manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates, specifically formulated for high-pressure service. This material achieves a coefficient of friction below 0.08 without any external hydrocarbon lubrication, completely eliminating oil vapor carryover into the nitrogen stream. At 1.60 MPa, the risk of oil contamination becomes exponentially more problematic because oil droplets are more difficult to separate at elevated pressure, and any contamination becomes concentrated in the compressed gas. The ZW-5.3/16’s native oil-free design achieves ISO 8573-1 Klasse 0-conformiteit without downstream filtration, a critical advantage for cylinder filling and high-purity process applications.

2. Two-Stage Three-Row Compression Architecture

De two-stage, three-row configuration of the ZW-5.3/16 is uniquely engineered to achieve the high pressure ratio required for 1.60 MPa discharge. The three-row arrangement provides superior force balance compared to two-row designs, reducing vibration transmission and permitting installation on lighter foundations. The staged compression with inter-stage cooling limits the discharge temperature of each stage to below 160°C, preserving the integrity of the PTFE sealing elements and extending valve plate life. This thermal management is particularly critical at high pressure ratios where adiabatic compression temperatures would otherwise exceed the safe operating limits of polymer-based seals.

3. Compact Design for Space-Constrained Installations

Bij 1947 × 1900 × 2580 mm, the ZW-5.3/16 occupies remarkably little floor space for a high-pressure compressor of this capability. The compact footprint is achieved through an optimized vertical crankcase design that minimizes the machine’s longitudinal dimension while maintaining adequate maintenance access. The 3.97-tonne weight permits transportation and positioning using standard forklift equipment, eliminating the need for overhead cranes or specialized rigging. This portability makes the ZW-5.3/16 ideal for containerized nitrogen supply systems, mobile cylinder filling stations, and retrofit installations in existing compressor houses with limited floor space.

4. Standard 380V Direct-On-Line Motor Drive

The ZW-5.3/16 is powered by a 55 kW, 380V, 50Hz three-phase induction motor rated to IEC 60034-1 IE3 efficiency class. 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 reduces both capital expenditure and commissioning complexity, making the ZW-5.3/16 an attractive option for facilities upgrading from bottled nitrogen or membrane generators to on-site high-pressure compression.

Toepassingsscenario's

High-Pressure Nitrogen Cylinder Filling

The ZW-5.3/16 is purpose-built for nitrogen cylinder filling stations serving industrial gas distributors, welding supply companies, and specialty gas laboratories. Its 1.60 MPa discharge pressure is sufficient to fill standard industrial nitrogen cylinders to 15 MPa working pressure through a high-pressure booster or cascade system. The 5.3 m³/min capacity supports a filling rate of approximately 20–25 cylinders per hour (40L, 15 MPa), making it suitable for medium-volume filling operations. The oil-free design is mandatory for cylinder filling because any oil contamination would be concentrated in the compressed gas and could contaminate downstream processes when the cylinder is used.

Petrochemical High-Pressure Nitrogen Injection

In petrochemical and refinery operations, the ZW-5.3/16 provides high-pressure nitrogen for reactor inerting, catalyst preservation, emergency vessel purging, and pipeline pressure testing. The 1.60 MPa discharge pressure is sufficient to overcome the pressure ratings of most process vessels and reactor systems, allowing direct nitrogen injection without intermediate boosting. The ZW-5.3/16 high-pressure nitrogen compressor is particularly valuable for emergency response scenarios where rapid nitrogen injection is required to inert a vessel or suppress a runaway reaction. The oil-free certification is mandatory because nitrogen at 1.60 MPa entering a catalyst bed or process stream must remain completely hydrocarbon-free.

Pharmaceutical & Biotechnology Process Gas

Pharmaceutical manufacturing facilities require high-purity nitrogen for sterile process inerting, lyophilization (freeze-drying), and aseptic filling operations. The ZW-5.3/16’s oil-free certification ensures compliance with FDA 21 CFR, EU GMP Annex 1, and pharmacopeial nitrogen standards. The 1.60 MPa pressure is adequate for feeding high-pressure nitrogen distribution manifolds serving multiple sterile processing suites, autoclaves, and freeze-dryers. The compact footprint allows installation within pharmaceutical cleanroom support areas or utility corridors where space is severely constrained.

Electronics & Semiconductor Manufacturing

Semiconductor fabrication facilities require high-pressure nitrogen for wafer handling systems, chemical vapor deposition (CVD) processes, and ion implantation chamber purging. The ZW-5.3/16’s 1.60 MPa discharge pressure is sufficient for feeding the high-pressure nitrogen headers that serve process tools requiring elevated pressure for pneumatic actuation or process gas delivery. The oil-free design is absolutely non-negotiable in semiconductor applications because even trace oil contamination can cause catastrophic defects in integrated circuits, leading to yield losses measured in millions of dollars.

Materiaal en constructie

The ZW-5.3/16 is constructed from premium materials selected for high-pressure nitrogen compatibility, corrosion resistance, and extended operational life:

Alle drukdragende componenten zijn ontworpen en vervaardigd in overeenstemming met ASME BPVC Sectie VIII Divisie 1 of de Chinese GB 150-normen. Elke lasverbinding ondergaat een 100%-radiografische inspectie (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.

Installatie- en onderhoudsrichtlijnen

Fundament- en ruimtelijke vereisten

The ZW-5.3/16 weighs 3.97 tonnes and features a compact vertical design with a low center of gravity. A reinforced concrete pad of 5–6 tonnes is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The three-row opposed-cylinder arrangement provides excellent force balance, minimizing vibration transmission. 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 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit feeds the cylinder jackets and intercooler in parallel. Water quality specifications: pH 6.5–8.5, total hardness < 300 mg/L as CaCO₃, chloride content < 50 mg/L (to prevent SS316 tube corrosion), 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.

Preventief onderhoudsschema

The oil-free design of the ZW-5.3/16 dramatically simplifies maintenance compared to lubricated alternatives. There are no oil changes, no oil analysis, no filter replacements, and no separator cartridge changes. The only consumable wear items are the PTFE-zuigerveren en geleidebanden, which typically achieve 3,000–5,000 hours of service under clean nitrogen conditions at high pressure.

Certificeringen voor naleving en veiligheid

The ZW-5.3/16 nitrogen compressor meets the following international standards and regulatory requirements:

Prestatie- en efficiëntieanalyse

The ZW-5.3/16 achieves a specific power consumption of approximately 10.38 kW per m³/min of nitrogen at 1.60 MPa discharge pressure. While this specific power is higher than low-pressure models due to the elevated pressure ratio, it remains competitive within the high-pressure oil-free piston compressor segment. For comparison, oil-lubricated reciprocating compressors at equivalent pressure ratios typically consume 11–13 kW/m³/min, and diaphragm compressors (often selected for high-pressure oil-free service) may exceed 15 kW/m³/min.

The primary economic advantage of the ZW-5.3/16 is not marginal energy savings but the eliminatie van oliegerelateerde verbruiksartikelen en apparatuur voor verdere zuivering. A typical oil-lubricated high-pressure compressor requires quarterly oil changes ($300–600/year), monthly oil analysis ($200–400/year), annual filter replacements ($500–1,000/year), and separator cartridge changes ($800–1,500/year). The ZW-5.3/16 eliminates all of these expenses, delivering total consumable savings of $1,800–$3,500 annually.

Additionally, the total cost of ownership for high-pressure nitrogen compression is further reduced by eliminating the need for downstream oil-removal equipment. At 1.60 MPa, oil-filtration systems become significantly more complex and expensive, often requiring multi-stage coalescing filters followed by activated carbon adsorbers. The ZW-5.3/16’s native oil-free design removes this capital and operating burden entirely.

Mogelijkheden voor maatwerk en OEM-productie

We provide flexible customization options to adapt the ZW-5.3/16 to specific installation constraints and end-user requirements:

• Pakketten op een frame: Pre-assembled compressor, motor, coolers, and control panel on a structural steel skid with forklift pockets and lifting eyes. Reduces field installation to electrical and cooling water connections only.
• Mobile Cylinder Filling Stations: The ZW-5.3/16 can be mounted on a road-legal trailer with integrated nitrogen storage, cylinder filling manifold, and diesel generator, creating a fully mobile high-pressure nitrogen supply unit for construction sites and emergency response.
• PLC en bewaking op afstand: Optional Siemens LOGO! or S7-1200 PLC with 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 84 dB(A) to 68 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments.
• OEM & Private Label: Custom paint schemes, branded nameplates, and localized documentation for gas equipment distributors and system integrators.

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

Case Study: Nitrogen Cylinder Filling Station Upgrade

Cliënt: An industrial gas distributor in Thailand serving welding, food packaging, and pharmaceutical customers

Uitdaging: The client’s existing oil-lubricated compressor (12 years in service) was experiencing oil carryover into filled nitrogen cylinders, causing customer complaints from pharmaceutical clients and requiring expensive cylinder cleaning procedures. The compressor was also undersized for growing demand, creating bottlenecks during peak filling periods.

Oplossing: Wij leverden een ZW-5.3/16 oil-free nitrogen compressor configured on a custom skid with integrated intercooler, aftercooler, and a high-pressure filling manifold capable of filling 40L cylinders to 15 MPa. The compact skid footprint fit within the existing filling bay without structural modifications.

Resultaten na 18 maanden:

• Cylinder oil contamination: Volledig geëlimineerd, achieving ISO 8573-1 Class 0 in all filled cylinders
• Customer complaints: Nul related to oil contamination or cylinder quality
• Filling capacity: Increased by 35%, reducing peak-period bottlenecks
• Onderhoudskosten: Verminderd met 40% through elimination of oil-related repairs and filter changes
• Cylinder cleaning expenses: Uitgeschakeld, saving $8,000/year

“The ZW-5.3/16 has completely transformed our cylinder filling operation. No more oil contamination issues, no more customer complaints, and our maintenance team spends half the time on compressor service. The payback was under 2 years.” — Operations Manager, Industrial Gas Distributor

Veelgestelde vragen en selectiegids

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Voor een volledig overzicht van onze industriële stikstofcompressor portfolio, including oil-free oxygen compressors, hydrogen compressors, and specialty gas solutions, please contact our engineering team.

Klaar om uw hogedrukstikstofsysteem te upgraden?

Our application engineers are available to evaluate your high-pressure nitrogen requirements, inlet conditions, and integration constraints. We provide complimentary technical proposals, layout drawings, and TCO analyses within 48 hours.

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