Sprężarka azotowa 3ZW-9,5/30 – trójstopniowy bezolejowy wzmacniacz N2 do zastosowań w procesach wysokociśnieniowych 3,00 MPa

Zaprojektowana do dostarczania 9,5 m³/min przy ciśnieniu tłoczenia 3,00 MPa, sprężarka 3ZW-9.5/30 to trzystopniowa, trzyrzędowa, bezolejowa tłokowa sprężarka azotu przeznaczona do wtrysku azotu pod bardzo wysokim ciśnieniem, stacji napełniania butli gazowych oraz wymagających zastosowań w procesach chemicznych. Charakteryzuje się brakiem zanieczyszczeń olejem, wielostopniową optymalizacją termodynamiczną i jest przeznaczona do ciągłej pracy w ekstremalnych warunkach ciśnienia.

Przegląd produktu

Ten 3ZW-9.5/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor technology, engineered specifically for applications demanding both substantial flow capacity and ultra-high discharge pressure. With a rated capacity of 9.5 m³/min i wyjątkowy Ciśnienie wylotowe 3,00 MPa, this unit occupies the high-pressure segment of our industrial nitrogen compressor portfolio, addressing the most demanding process requirements in chemical synthesis, gas cylinder filling, and high-pressure inerting operations.

What distinguishes the 3ZW-9.5/30 from conventional alternatives is its three-stage compression architecture combined with a fully oil-free compression pathway. The piston rings and rider bands in all three stages are precision-machined from advanced self-lubricating PTFE composite materials that operate without hydrocarbon lubricants. This intrinsic oil-free characteristic ensures the nitrogen stream remains completely uncontaminated, achieving Certyfikat ISO 8573-1 klasy 0 natively. For operators in pharmaceutical manufacturing, electronics fabrication, and food-grade gas production, this eliminates the capital expenditure and ongoing maintenance burden of downstream oil-removal filtration systems that would be mandatory with lubricated alternatives.

Kompresor wykorzystuje trzystopniowy, trzyrzędowy (三列三级) configuration that is thermodynamically essential for achieving the 3.00 MPa discharge pressure from typical inlet conditions. The overall pressure ratio of approximately 30:1 to 60:1 is distributed across three compression cylinders, with each stage operating at a manageable pressure ratio. Independent intercoolers between stages remove the substantial heat of compression, maintaining discharge temperatures within safe operating limits and preserving the integrity of the PTFE sealing elements. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120 000 godzin zgodnie ze standardowymi protokołami konserwacyjnymi.

Technical Specifications – 3ZW-9.5/30

* Wszystkie parametry podano w standardowych warunkach odniesienia (ISO 1217, załącznik C). Rzeczywista wydajność może się różnić w zależności od wysokości nad poziomem morza, temperatury otoczenia i warunków na wlocie.

Kluczowe cechy i zalety inżynieryjne

1. Trójstopniowa kompresja dla ultrawysokiego ciśnienia

The 3ZW-9.5/30 employs a three-stage compression architecture that is thermodynamically essential for achieving 3.00 MPa discharge pressure from atmospheric or low-pressure inlet conditions. The overall pressure ratio is distributed across three compression cylinders—low-pressure, medium-pressure, and high-pressure—each operating at a pressure ratio of approximately 3:1 to 4:1. This staged approach limits the discharge temperature of each stage to below 155°C, preventing thermal degradation of the PTFE sealing elements and extending valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios. Two independent intercoolers between stages remove the heat of compression, maintaining optimal thermodynamic efficiency throughout the compression path.

2. Advanced Oil-Free PTFE Sealing for High-Pressure Service

All three compression stages utilize a proprietary samosmarujący pierścień tłokowy i zespół nośny manufactured from high-density PTFE composites reinforced with glass fiber and bronze particulates. This material achieves a coefficient of friction below 0.06 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 problematic. The oil-free design achieves Certyfikacja ISO 8573-1 klasy 0 natywnie, eliminating the need for downstream coalescing filters, activated carbon adsorbers, and oil monitoring instrumentation that would be mandatory with lubricated alternatives. The PTFE formulation is specially rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity under the extreme thermal stress of ultra-high-pressure compression.

3. Three-Row Force-Balanced Frame Design

Główna rama jest odlana z Żeliwo szare GG25 (equivalent to ASTM A48 Class 30B) with reinforced wall sections and integral cooling water passages. The układ trzyrzędowy z cylindrami przeciwsobnymi provides progressive force cancellation across the crankshaft, with the first and third cylinders opposing the second cylinder to achieve near-complete first-order force balance. This mechanical sophistication reduces the unbalanced inertia forces transmitted to the foundation by over 85% compared to single-row designs of equivalent capacity. The result is a remarkably smooth-running high-pressure compressor that can operate on a standard reinforced concrete pad without the massive inertia blocks typically required for high-pressure reciprocating machines.

4. Standard 380V Drive with High Efficiency

The 3ZW-9.5/30 is driven by a 110 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. Despite the substantial power requirement for three-stage compression, the standard low-voltage configuration integrates directly into existing 380V industrial distribution panels without requiring medium-voltage switchgear. This electrical accessibility makes the 3ZW-9.5/30 available to a wide range of industrial facilities, from small gas filling stations to medium-scale chemical plants, without electrical infrastructure upgrades.

Scenariusze zastosowań

Stacje napełniania butli z azotem wysokociśnieniowym

The 3ZW-9.5/30 is purpose-built for operacje napełniania butli z azotem where gas must be compressed to the 15–20 MPa pressure required for standard industrial gas cylinders. While the compressor’s 3.00 MPa discharge pressure does not reach final cylinder filling pressure directly, it serves as a highly efficient primary booster that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. The three-stage design is particularly advantageous for cylinder filling because it provides a stable, cool intermediate pressure that improves the efficiency and longevity of the final high-pressure stage. The oil-free certification is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users, potentially compromising critical processes in healthcare, electronics, and food applications.

Synteza chemiczna i inertyzacja reaktorów wysokociśnieniowych

W zakładach przetwórstwa chemicznego 3ZW-9.5/30 nitrogen compressor zapewnia azot pod bardzo wysokim ciśnieniem high-pressure reactor inerting, catalyst bed preservation, and supercritical fluid extraction processes. The 3.00 MPa discharge pressure is sufficient to maintain inert atmospheres in reactors operating at pressures up to 2.5 MPa, ensuring positive nitrogen flow into the vessel even during pressure transients. The three-stage design provides excellent pressure stability, which is critical for chemical processes where nitrogen pressure fluctuations could affect reaction kinetics or product quality. The oil-free design prevents catalyst poisoning and product contamination that would occur with even trace oil carryover.

Oil & Gas Pipeline Pressure Testing

In the oil and gas industry, nitrogen is the preferred medium for hydrostatic and pneumatic pressure testing of pipelines, pressure vessels, and wellhead equipment because it is inert and avoids the corrosion and contamination risks associated with water testing. The 3ZW-9.5/30’s 3.00 MPa discharge pressure is suitable for testing pipelines and equipment rated up to API Class 600 (2.5 MPa working pressure). The oil-free design is essential because any oil contamination in the test nitrogen could be mistaken for pipeline corrosion products or residual hydrocarbons, leading to false test results and costly re-testing. The 9.5 m³/min capacity allows rapid pressurization of large-diameter pipelines, reducing test cycle time and improving project productivity.

Electronics Ultra-High-Purity Nitrogen Supply

Semiconductor fabrication facilities require nitrogen at elevated pressure for wafer transport system pressurization, chemical vapor deposition (CVD) chamber purge, and high-pressure drying of photolithography equipment. The 3ZW-9.5/30’s 3.00 MPa discharge pressure drives high-velocity nitrogen jets used in precision cleaning and particle removal applications. The oil-free design is absolutely non-negotiable in semiconductor manufacturing where even sub-ppb oil contamination can cause catastrophic defects in nanometer-scale integrated circuits. The three-stage compression provides exceptionally stable discharge pressure, which is critical for maintaining consistent process conditions in deposition and etching equipment.

Materiały i budownictwo

The 3ZW-9.5/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, thermal resistance, and extended operational life:

Wszystkie elementy przenoszące ciśnienie są projektowane i wytwarzane w ścisłej zgodności z ASME BPVC Sekcja VIII Dział 1 lub chińskie normy GB 150. Każde złącze spawane poddawane jest badaniu radiograficznemu (RT) 100% zgodnie z sekcją V, artykułem 2 normy ASME, a każdy ukończony zbiornik ciśnieniowy poddawany jest próbie ciśnieniowej hydrostatycznej przy 1,5-krotności maksymalnego dopuszczalnego ciśnienia roboczego (MAWP) przez minimalny okres przetrzymania 30 minut. Systemy rurociągów wysokociśnieniowych są wykonane z bezszwowej stali SS316 z połączeniami kołnierzowymi ANSI klasy 900, co gwarantuje szczelność przy ciśnieniu roboczym 3,00 MPa.

Wytyczne dotyczące instalacji i konserwacji

Wymagania dotyczące fundamentów i konstrukcji

The 3ZW-9.5/30 has a dry weight of 3.50 tonnes and a center of gravity approximately 850 mm above the baseplate. Despite the three-stage high-pressure operation, the three-row opposed-cylinder design achieves excellent force balance, permitting installation on a blok bezwładnościowy z betonu zbrojonego o masie 6–8 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. The high-pressure discharge piping (3.00 MPa) requires special attention to support and anchoring to prevent vibration-induced fatigue and ensure personnel safety.

Projektowanie układu chłodzenia wodnego

Zapotrzebowanie na wodę chłodzącą wynosi około 22 m³/godz. at an inlet temperature not exceeding 32°C. The water distribution circuit supplies three cylinder jacket circuits and two intercoolers in a parallel/series hybrid arrangement optimized for thermal management. Given the extreme pressure ratio, both intercoolers are critical for preserving PTFE ring integrity 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 is strongly recommended.

Harmonogram konserwacji zapobiegawczej

The oil-free design of the 3ZW-9.5/30 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 Pierścienie tłokowe i opaski zaciskowe PTFE, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions. The high-pressure valve plates in the third stage may require more frequent inspection (every 2,000 hours) due to the extreme mechanical stress at 3.00 MPa, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

Certyfikaty zgodności i bezpieczeństwa

The 3ZW-9.5/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Analiza wydajności i efektywności

The 3ZW-9.5/30 achieves a specific power consumption of approximately 11.58 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 through three stages. Within the high-pressure oil-free 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, a diaphragm compressor delivering equivalent capacity and pressure would typically consume 16–20 kW/m³/min and cost 4–6 times more in capital expenditure.

Over an 8,000-hour annual operating schedule, the 3ZW-9.5/30’s efficiency advantage versus diaphragm alternatives yields approximately 340,000–530,000 kWh of annual energy savings. At $0.08/kWh, this represents $27,200–$42,400 in direct electricity cost reduction per year. However, the primary economic driver for 3ZW-9.5/30 selection is typically the combination of high capacity, moderate capital cost, and native oil-free operation that is unattainable with other compressor technologies at this pressure level. The całkowity koszt posiadania dla sprężania azotu pod bardzo wysokim ciśnieniem is reduced by an estimated 40–50% over a 10-year operational life when the three-stage piston design is compared to multi-diaphragm systems.

The three-stage design also provides superior pressure stability compared to single-stage high-pressure compressors, which is critical for process applications where pressure fluctuations could affect product quality or process safety. The inter-stage cooling ensures that each stage operates at optimal thermodynamic efficiency, minimizing the overall power consumption for the required pressure rise.

Możliwości personalizacji i OEM

We offer comprehensive customization options to adapt the 3ZW-9.5/30 to specific site conditions, integration requirements, and end-user specifications:

• Pakiety „pod klucz” montowane na płozach: Pre-assembled compressor, motor, three coolers, 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 60%.
• Konfiguracje stref niebezpiecznych: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks with emergency isolation valves.
• Zaawansowana kontrola procesów: 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 sequencing and high-pressure safety interlocks including emergency blowdown.
• Ochrona środowiska: Powłoki morskie C5-M do instalacji nadbrzeżnych; komponenty elektryczne przystosowane do warunków tropikalnych w temperaturze otoczenia 55°C; obudowy akustyczne o stopniu ochrony IP54 redukujące hałas z 85 dB(A) do 72 dB(A) w odległości 1 metra.
• OEM i marka własna: Niestandardowe kolory farb, markowe tabliczki znamionowe i lokalna dokumentacja dla dystrybutorów sprzętu gazowego i integratorów systemów.

Dostępne są konfiguracje niestandardowe MOQ 1 jednostka. Engineering proposals are typically delivered within 5–7 business days. Standard delivery time is 12–14 weeks; repeat orders are delivered in 8–10 weeks from order confirmation.

Case Study: Industrial Gas Cylinder Filling Station Upgrade

Klient: A major industrial gas distributor in Indonesia serving manufacturing, healthcare, and electronics sectors

Wyzwanie: The client’s existing cylinder filling station used an oil-lubricated two-stage compressor feeding a diaphragm filling compressor. Oil contamination from the primary compressor was migrating through the system, causing the diaphragm compressor’s final purification beds to require replacement every 4 months instead of the designed 18-month interval. Oil levels in filled cylinders reached 2.0 mg/m³, exceeding the 0.1 mg/m³ specification for medical and electronics-grade nitrogen. The diaphragm compressor was also operating at reduced efficiency due to oil-fouled heat exchangers.

Rozwiązanie: Dostarczyliśmy 3ZW-9.5/30 oil-free nitrogen compressor as the primary booster, replacing the oil-lubricated unit. The three-stage design provided a stable 3.00 MPa intermediate pressure that improved the downstream diaphragm compressor’s efficiency by 15%. The oil-free design eliminated the need for activated carbon purification beds entirely. The unit was configured on a custom skid with integrated coolers and a Siemens S7-1200 PLC with remote monitoring.

Wyniki ilościowe po 18 miesiącach:

• Nitrogen oil content in filled cylinders: Reduced from 2.0 mg/m³ to <0.01 mg/m³, osiągając klasę 0 normy ISO 8573-1
• Activated carbon bed replacement: Całkowicie wyeliminowane, oszczędzając $18 000/rok na materiałach eksploatacyjnych
• Diaphragm compressor efficiency: Improved by 15%, reducing its power consumption by 22 kW
• Customer complaints and returns: Zero since commissioning, with contracts renewed for 3 additional years
• Okres zwrotu: 2.3 years based on cost savings and contract renewals

“The 3ZW-9.5/30 has completely transformed our filling station. The oil-free design eliminated our quality control issues overnight, and the three-stage compression has made our downstream equipment run more efficiently than ever. Our medical gas customers have noticed the difference immediately.” — Operations Director, Industrial Gas Distributor

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