Descrição
Compressor de nitrogênio ZW-0.97/7.5~30 – Booster de N2 compacto, isento de óleo e com entrada variável para recirculação de média pressão
Projetado para fornecer 0,97 m³/min a uma pressão de descarga de 3,00 MPa com capacidade de entrada de 0,75 MPa, o ZW-0.97/7.5~30 é um compressor de nitrogênio de pistão isento de óleo, de dois estágios e fileira única, desenvolvido para reciclagem de nitrogênio em pequena escala, circuitos de reforço de liquefação de gás e aplicações de processo de média pressão com condições de entrada variáveis. Zero contaminação por óleo, tamanho ultracompacto e otimizado para operação contínua.
Visão geral do produto
O ZW-0.97/7.5~30 nitrogen compressor is a compact yet capable solution within our oil-free piston compressor family, distinguished by its variable inlet pressure capability spanning from 0.75 MPa up to the discharge pressure of 3.00 MPa. With a rated capacity of 0.97 m³/min e uma pressão de descarga de 3,00 MPa, this unit occupies the entry-level segment of our high-pressure nitrogen compressor portfolio while maintaining the same engineering rigor as our larger models.
What makes the ZW-0.97/7.5~30 unique is its ability to accept inlet nitrogen at pressures up to 0.75 MPa, as indicated by the model designation “7.5~30” (representing inlet pressure range of 0.75 MPa to 3.0 MPa). This variable inlet capability eliminates the need for upstream pressure reduction when feeding from medium-pressure nitrogen headers or process vents, improving overall system efficiency and reducing pressure losses. The compressor can also operate from atmospheric or low-pressure inlet when required, providing exceptional operational flexibility for small-scale installations.
O compressor emprega um two-stage, single-row (二列一级) configuration that is optimized for the moderate pressure ratio required when boosting from 0.75 MPa to 3.00 MPa. The single-row design minimizes mechanical complexity and footprint while the two-stage arrangement ensures efficient thermodynamic performance and manageable discharge temperatures. Each stage features independent cooling, preserving the integrity of the PTFE sealing elements even under sustained operation at elevated pressure.
Technical Specifications – ZW-0.97/7.5~30
| Parâmetro | Valor | Unidade |
|---|---|---|
| Modelo | ZW-0.97/7.5~30 | – |
| Padrão | Two-stage, Single-row (二列一级) | – |
| Capacidade | 0.97 (inlet 0.75 MPa) | m³/min |
| Pressão de descarga | 3.00 | MPa |
| Inlet Pressure Range | 0.75 ~ 3.00 | MPa |
| Dimensões do compressor (C × L × A) | 2035 × 1240 × 2234 | mm |
| Peso | 2.60 | t |
| Poder | 45 | kW |
| Tensão | 380 | V |
| Meio gasoso | Nitrogênio (N₂) | – |
| Lubrificação | Sem óleo | – |
* All specifications are rated at standard reference conditions (ISO 1217, Annex C). Actual performance may vary based on site altitude, ambient temperature, and inlet conditions. Capacity is specified at 0.75 MPa inlet pressure; actual capacity varies with inlet pressure.
Principais características e vantagens de engenharia
1. Variable Inlet Pressure Capability (0.75–3.00 MPa)
The ZW-0.97/7.5~30 is uniquely engineered to accept inlet nitrogen across a broad pressure range from 0.75 MPa up to 3.00 MPa. This variable inlet capability is achieved through a robust valve design and cylinder sizing that accommodates varying suction densities without mechanical distress. When fed from a medium-pressure nitrogen header at 0.75 MPa, the compressor operates at its rated 0.97 m³/min capacity. As inlet pressure increases toward the discharge pressure, the compressor transitions into a pressure-maintaining or recycle mode with progressively reduced power consumption. This flexibility eliminates the need for upstream pressure regulators or throttling valves that would waste energy and create noise, making the ZW-0.97/7.5~30 ideal for nitrogen recycle loops and process systems with variable upstream pressure.
2. Ultra-Compact Footprint for Space-Constrained Installations
No 2035 × 1240 × 2234 mm, the ZW-0.97/7.5~30 occupies less than 2.5 m² of floor space, making it one of the most compact high-pressure oil-free nitrogen compressors available. This dimensional efficiency is achieved through a vertically oriented crankcase design and a single-row cylinder arrangement that minimizes the machine’s longitudinal footprint. At just 2.60 tonnes, the unit can be transported and positioned using standard forklift equipment, eliminating the need for overhead cranes or specialized rigging. This compact form factor is particularly valuable for retrofit installations in existing process plants, containerized systems, and mobile nitrogen supply units where floor space is at a premium.
3. Oil-Free PTFE Composite Sealing for High-Pressure Service
The ZW-0.97/7.5~30 utilizes a proprietary conjunto de anel de pistão autolubrificante e cinta de guia manufactured from high-performance PTFE composites reinforced with glass fiber and bronze particulates. This material achieves a coefficient of friction below 0.06 without any external hydrocarbon lubrication, ensuring the nitrogen stream remains completely free of oil contamination. At 3.00 MPa discharge pressure, the partial pressure of any oil vapor would be significantly magnified, making oil-free design absolutely essential for applications requiring high-purity nitrogen. The PTFE formulation is specifically rated for continuous operation at temperatures up to 180°C, ensuring reliable sealing integrity under the thermal stress of high-pressure compression.
4. Standard 380V Drive with Low Power Consumption
The ZW-0.97/7.5~30 is driven by a 45 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. The modest power requirement of 45 kW makes this unit accessible to virtually any industrial facility with standard 380V distribution, without requiring electrical infrastructure upgrades or medium-voltage switchgear. The low power consumption also translates to lower operating costs and reduced cooling requirements, making the ZW-0.97/7.5~30 an economically attractive option for small to medium nitrogen systems.
Cenários de aplicação
Small-Scale Nitrogen Recycle & Recovery
In small chemical process plants and gas treatment facilities, the ZW-0.97/7.5~30 serves as a nitrogen recycle compressor that recovers nitrogen from process vents and boosts it back to the required distribution pressure. The variable inlet capability is critical in these applications because the recovered nitrogen may be at any pressure between atmospheric and the process operating pressure. The compressor automatically adapts to the available inlet pressure, maintaining efficient operation across the full range. This recycle capability reduces nitrogen consumption by 30–50% compared to once-through systems, delivering substantial operating cost savings for small-scale operations where every efficiency gain matters.
Gas Liquefaction & Cryogenic Booster Duty
In small-scale nitrogen liquefaction plants and cryogenic systems, the ZW-0.97/7.5~30 nitrogen booster compresses nitrogen from the liquefier vaporizer or storage tank 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, or supplying high-pressure process equipment. The variable inlet capability allows the compressor to accept nitrogen directly from the liquefier at its operating pressure, eliminating intermediate pressure reduction and improving overall plant efficiency.
Pilot Plant & R&D High-Pressure Nitrogen Supply
Research laboratories and pilot-scale chemical plants require high-pressure nitrogen for high-pressure reactor inerting, catalyst testing under pressure, and supercritical fluid experiments. The ZW-0.97/7.5~30’s compact footprint and standard 380V electrical supply make it ideal for installation in laboratory utility rooms or pilot plant buildings. The 3.00 MPa discharge pressure is adequate for most pilot-scale high-pressure applications, while the oil-free certification ensures that nitrogen purity meets the stringent requirements of research-grade experiments and analytical instrumentation. The variable inlet capability is particularly valuable in R&D environments where experimental conditions change frequently.
Medium-Pressure Header Pressure Maintenance
Industrial facilities with medium-pressure nitrogen distribution headers (0.75–1.50 MPa) often require a pressure maintenance compressor to compensate for demand fluctuations and pipeline losses. The ZW-0.97/7.5~30 can accept nitrogen directly from the header at its operating pressure and boost it to 3.00 MPa for high-pressure consumers or back into the header to maintain pressure during peak demand periods. This dual-mode operation provides exceptional operational flexibility and reduces the need for separate compressor units, making it an economically efficient solution for small to medium facilities.
Materiais e construção
The ZW-0.97/7.5~30 is constructed from materials selected for high-pressure nitrogen compatibility, thermal resistance, and compact structural integrity:
| Componente | Material | Especificação |
|---|---|---|
| Bloco de Cilindros (LP) | Ferro fundido cinzento | GG25 / HT250, espessura de parede padrão |
| Bloco de Cilindros (HP) | Ferro fundido cinzento | GG25 / HT250, parede reforçada + nervuras |
| Cambota | Aço liga forjado | 42CrMo4, Q&T, balanceado dinamicamente |
| Anéis de Pistão | Compósito de PTFE-Vidro-Bronze | High-pressure rated, self-lubricating, 180°C max |
| Pulseiras de motociclista | Compósito de PTFE | Guia do pistão, anti-arranhões |
| Placas de válvulas | Aço inoxidável | Aço inoxidável 316, design de anel concêntrico de alta pressão |
| Intercooler | Carcaça em aço carbono / Tubos em aço inoxidável 316 | ASME VIII Div.1, 1.5× hydrotest |
| Resfriador posterior | Carcaça em aço carbono / Tubos em aço inoxidável 316 | Tubo aletado de alta pressão, água de refrigeração a 32 °C |
| Tubulação de Alta Pressão | Aço inoxidável sem emendas | SS316, ANSI Class 600 flanges |
Todos os componentes que suportam pressão são projetados e fabricados de acordo com ASME BPVC Seção VIII Divisão 1 or Chinese GB 150 standards. Every weld joint undergoes 100% radiographic inspection (RT) per ASME Section V, Article 2, and each completed pressure vessel is subjected to a hydrostatic pressure test at 1.5 times the maximum allowable working pressure (MAWP) for a minimum hold period of 30 minutes. High-pressure piping systems are fabricated from seamless SS316 with ANSI Class 600 flanged connections to ensure leak-tight integrity at 3.00 MPa operating pressure.
Diretrizes de Instalação e Manutenção
Requisitos de Fundação e Espaciais
The ZW-0.97/7.5~30 has a dry weight of 2.60 tonnes and a center of gravity approximately 700 mm above the baseplate. A reinforced concrete pad of 4–5 tonnes is sufficient for stable operation, mounted on elastomeric vibration isolators (natural frequency 8–12 Hz). The single-row design generates moderate unbalanced forces that are easily managed with standard foundation practices. Minimum clearance requirements: 1.0 m on the non-drive side for valve access, 0.8 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 and anchored to prevent vibration-induced fatigue at 3.00 MPa.
Especificações da água de resfriamento
A demanda de água para resfriamento é de aproximadamente 8 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and intercooler in parallel. Given the high pressure ratio, the intercooler is critical for thermal management and must receive priority cooling water flow. 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 recommended for sites with marginal water quality.
Cronograma de Manutenção Preventiva
| Intervalo | Item de serviço | Ação necessária |
|---|---|---|
| Diário | Inspeção Operacional | Verificar vibração, ruído anormal, fluxo de água de refrigeração, pressão de descarga e temperatura. |
| 250 horas | Inspeção da placa da válvula | Remova e inspecione as válvulas de sucção/descarga quanto a depósitos de carbono, fadiga da mola e rachaduras. |
| 1.000 horas | Avaliação do desgaste dos anéis do pistão | Meça a folga na ranhura do anel; substitua os anéis se a folga exceder 0,20 mm. |
| 3.000 horas | Revisão Intermediária | Substitua todos os anéis de pistão, anéis de guia e conjuntos de placas de válvulas. |
| 6.000 horas | Revisão geral | Inspecione os munhões do virabrequim, meça a folga dos mancais principais e substitua os mancais se a folga for superior a 0,08 mm. |
The oil-free design of the ZW-0.97/7.5~30 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 Anéis de pistão e anéis de guia de PTFE, which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions. The high-pressure valve plates may require more frequent inspection than low-pressure equivalents due to increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems.
Certificações de Conformidade e Segurança
The ZW-0.97/7.5~30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:
ASME BPVC Seção VIII Div.1, GB 150-2011, PED 2014/68/EU Módulo A
IEC 60034-1 (eficiência IE3), IEC 60204-1, ISO 12100 segurança de máquinas
ISO 8573-1 Classe 0 (Teor de Óleo), testado independentemente pela TÜV Rheinland.
ISO 9001:2015, ISO 14001:2015
Nitrogen is classified as a simple asphyxiant gas. At 3.00 MPa discharge pressure, the risk of rapid gas release and oxygen displacement is significantly elevated. All ZW-0.97/7.5~30 installations must incorporate continuous oxygen deficiency monitoring in the compressor room and adjacent areas. High-pressure discharge piping must be equipped with pressure relief valves rated at 110% of MAWP and rupture discs as secondary protection. 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 high-pressure gas safety protocols before operating or maintaining this equipment.
Análise de desempenho e eficiência
The ZW-0.97/7.5~30 achieves a specific power consumption of approximately 46.39 kW per m³/min of nitrogen at 3.00 MPa discharge pressure from 0.75 MPa inlet. While this specific power appears high in absolute terms, the true efficiency advantage lies in the ability to accept high-pressure inlet without energy-wasting pressure reduction. When compared to systems that throttle 0.75 MPa nitrogen down to atmospheric pressure before re-compressing to 3.00 MPa, the ZW-0.97/7.5~30 saves approximately 45–55% of the compression energy by utilizing the available inlet pressure directly.
Over an 8,000-hour annual operating cycle in a typical nitrogen recycle application, the ZW-0.97/7.5~30’s variable inlet capability yields approximately 80,000–120,000 kWh of energy savings compared to systems requiring upstream pressure reduction. At $0.08/kWh, this represents $6,400–$9,600 in annual electricity cost reduction. When combined with the elimination of oil-related consumables and the avoidance of downstream purification equipment, the total cost of ownership for nitrogen recycle compression is reduced by an estimated 30–40% over a 10-year operational life.
The absence of oil in the compression path is particularly valuable in recycle applications because any oil contamination would accumulate in the closed nitrogen loop, progressively degrading product quality and potentially contaminating process equipment. The ZW-0.97/7.5~30’s native oil-free design ensures that nitrogen purity is maintained indefinitely in recycle service.
Personalização e capacidades OEM
We offer flexible customization options to adapt the ZW-0.97/7.5~30 to specific site conditions and integration requirements:
- Pacotes montados em skid: Pre-assembled compressor, motor, coolers, instrumentation, and control panel on a structural steel skid with forklift pockets. Reduces field installation to electrical and cooling water connections only.
- Unidades móveis em reboque: The ZW-0.97/7.5~30 can be mounted on a road-legal trailer with integrated diesel generator, cooling system, and nitrogen storage, creating a fully mobile nitrogen supply unit for construction sites, pipeline maintenance, and emergency response.
- PLC e monitoramento remoto: Optional Siemens LOGO! or S7-1200 PLC with HMI touchscreen, Ethernet connectivity, and SMS/email alarms. Compatible with Modbus TCP/IP for SCADA integration.
- Cabines acústicas: Cabine acústica compacta com classificação IP54, que reduz o ruído de 82 dB(A) para 68 dB(A) a 1 metro, adequada para instalações internas em ambientes sensíveis ao ruído, como laboratórios e salas de máquinas adjacentes a escritórios.
- OEM e marca própria: Custom paint schemes, branded nameplates, and localized documentation for gas equipment distributors and system integrators.
Configurações personalizadas estão disponíveis em Quantidade mínima de encomenda: 1 unidadeAs propostas de engenharia são geralmente entregues em 3 a 5 dias úteis. O prazo de entrega padrão é de 10 a 12 semanas; a entrega expressa em até 8 semanas está disponível para pedidos qualificados.
Case Study: Pilot Plant Nitrogen Recycle Optimization
Cliente: A specialty chemical R&D facility in Singapore operating multiple pilot-scale high-pressure reactors
Desafio: The facility was purchasing high-pressure nitrogen cylinders for reactor inerting and purge operations, consuming approximately 200 cylinders per month at a cost of $15,000/month. The spent nitrogen was vented to atmosphere at 0.60–0.90 MPa after passing through the reactors, representing a significant waste of both gas and energy. The facility wanted to recover and recycle this nitrogen but needed a compact compressor capable of accepting variable inlet pressure and boosting it to 2.50 MPa for re-use in the high-pressure reactor feed system.
Solução: Nós fornecemos um ZW-0.97/7.5~30 oil-free nitrogen compressor configured on a compact skid with integrated intercooler, aftercooler, and a Siemens LOGO! PLC control panel. The variable inlet capability allowed the compressor to accept nitrogen directly from the reactor vent header at whatever pressure was available (0.60–0.90 MPa), eliminating the need for upstream pressure regulation. A 0.5 m³ surge vessel was installed upstream to dampen pressure fluctuations from the batch reactor cycle.
Resultados quantificados após 18 meses:
- Nitrogen cylinder purchases: Reduced by 72% (from 200 to 56 cylinders/month), saving $10,800/month
- Nitrogen vent emissions: Reduced by 72%, improving environmental compliance
- Oil contamination in recycled nitrogen: <0.01 mg/m³, ensuring no reactor contamination
- Compressor availability: 97.8% over 18 months, with only scheduled maintenance downtime
- Período de retorno do investimento: 1.4 years based on cylinder cost savings alone
“The ZW-0.97/7.5~30 has transformed our nitrogen supply from a recurring expense into a closed-loop system. We’ve cut our cylinder purchases by nearly three-quarters, and the compact size meant we could install it in our existing utility room without any building modifications. The variable inlet feature was the key that made this project work.” — R&D Operations Manager, Specialty Chemical Facility
Perguntas frequentes e guia de seleção
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Ready to Optimize Your Small-Scale Nitrogen Recycle System?
Our application engineers are standing by to evaluate your nitrogen flow requirements, inlet pressure conditions, discharge pressure targets, and integration constraints. We provide complimentary technical proposals, layout drawings, piping and instrumentation diagrams (P&IDs), and detailed total cost of ownership (TCO) analyses within 48 hours of receiving your inquiry.
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