Descrição
Compressor de nitrogênio ZW-2.1/8~25 – Booster de N2 isento de óleo com entrada variável para uma ampla gama de aplicações industriais.
Projetado para fornecer 2,1 m³/min a uma pressão de descarga de 2,50 MPa com capacidade de entrada de 0,80 MPa, o ZW-2.1/8~25 é um compressor de nitrogênio de pistão de fileira única e dois estágios, isento de óleo, projetado para reciclagem de nitrogênio, reforço de liquefação de gás e aplicações de processo de alta pressão com condições de entrada variáveis. Sem contaminação por óleo, tamanho compacto e otimizado para operação contínua.
Visão geral do produto
O ZW-2.1/8~25 nitrogen compressor represents a specialized solution within our oil-free piston compressor portfolio, distinguished by its variable inlet pressure capability ranging from 0.80 MPa up to the discharge pressure of 2.50 MPa. With a rated capacity of 2.1 m³/min e uma pressão de descarga de 2.50 MPa, this unit is purpose-built for nitrogen recycle applications, gas liquefaction booster circuits, and process systems where the inlet nitrogen is already partially compressed.
What makes the ZW-2.1/8~25 unique is its ability to accept inlet nitrogen at pressures up to 0.80 MPa, as indicated by the model designation “8~25” (representing inlet pressure range of 0.8 MPa to 2.5 MPa). This variable inlet capability eliminates the need for upstream pressure reduction when feeding from medium-pressure nitrogen headers, improving overall system efficiency and reducing pressure losses. The compressor can also operate as a conventional booster from atmospheric or low-pressure inlet when required, providing exceptional operational flexibility.
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 0.80 MPa to 2.50 MPa. The single-row design simplifies the mechanical architecture 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.
Technical Specifications – ZW-2.1/8~25
| Parâmetro | Valor | Unidade |
|---|---|---|
| Modelo | ZW-2.1/8~25 | – |
| Padrão | Two-stage, Single-row (二列一级) | – |
| Capacidade | 2.1 (inlet 0.80 MPa) | m³/min |
| Pressão de descarga | 2.50 | MPa |
| Inlet Pressure Range | 0.80 ~ 2.50 | MPa |
| Dimensões do compressor (C × L × A) | 1900 × 1296 × 2290 | mm |
| Peso | 2.60 | t |
| Poder | 75 | 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 0.80 MPa inlet pressure; actual capacity varies with inlet pressure.
Principais características e vantagens de engenharia
1. Variable Inlet Pressure Capability (0.80–2.50 MPa)
The ZW-2.1/8~25 is uniquely engineered to accept inlet nitrogen across a broad pressure range from 0.80 MPa up to 2.50 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 0.80 MPa, the compressor operates at its rated 2.1 m³/min capacity. When inlet pressure increases toward the discharge pressure, the compressor transitions into a pressure-maintaining or recycle mode with 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-2.1/8~25 ideal for nitrogen recycle loops and process systems with variable upstream pressure.
2. Oil-Free PTFE Composite Sealing System
The ZW-2.1/8~25 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 2.50 MPa discharge pressure, the risk of oil vapor carryover is significantly magnified compared to low-pressure applications, making the oil-free design not merely advantageous but fundamentally essential. The PTFE formulation is rated for continuous operation at temperatures up to 180°C, ensuring reliable sealing integrity under the thermal stress of high-pressure compression.
3. Compact Single-Row Design for Space Efficiency
O two-stage, single-row (二列一级) architecture of the ZW-2.1/8~25 is mechanically simpler than two-row designs, resulting in a more compact footprint and lower weight. At 1900 × 1296 × 2290 mm and 2.60 tonnes, the unit occupies less than 2.5 m² of floor space and can be transported and positioned using standard forklift equipment. The single-row configuration is well-suited for the moderate flow rate of 2.1 m³/min, where the inertial forces are manageable without the complexity of opposed-cylinder arrangements. This dimensional efficiency makes the ZW-2.1/8~25 particularly attractive for retrofit installations in existing process plants where machinery room space is limited.
4. Acionamento de motor industrial padrão de 380 V
The ZW-2.1/8~25 is driven by a Motor de indução trifásico de 75 kW, 380 V, 50 Hz 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 regardless of their electrical infrastructure scale.
Cenários de aplicação
Nitrogen Recycle & Pressure Boosting Loops
In chemical process plants and gas treatment facilities, the ZW-2.1/8~25 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 nitrogen systems, delivering substantial operating cost savings and environmental benefits.
Gas Liquefaction Booster Duty
In small-scale nitrogen liquefaction plants, the ZW-2.1/8~25 nitrogen booster compresses nitrogen from the liquefier vaporizer or storage tank to the pressure required for distribution or further processing. The 2.50 MPa discharge pressure is sufficient for feeding high-pressure nitrogen into cryogenic storage systems or for driving nitrogen through heat exchangers and process equipment. The variable inlet capability allows the compressor to accept nitrogen directly from the liquefier at its operating pressure, eliminating the need for intermediate pressure reduction and improving overall liquefaction plant efficiency.
Medium-Pressure Header Pressure Maintenance
Industrial facilities with medium-pressure nitrogen distribution headers (0.80–1.50 MPa) often require a pressure maintenance compressor to compensate for demand fluctuations and pipeline losses. The ZW-2.1/8~25 can accept nitrogen directly from the header at its operating pressure and boost it to 2.50 MPa for high-pressure consumers or back into the header to maintain pressure during peak demand periods. This dual-mode operation—acting as both a booster and a pressure maintainer—provides exceptional operational flexibility and reduces the need for separate compressor units.
Laboratory & Pilot Plant High-Pressure Nitrogen
Research laboratories and pilot-scale chemical plants require high-pressure nitrogen for high-pressure reactor inerting, catalyst testing, and supercritical fluid applications. The ZW-2.1/8~25’s compact footprint and standard 380V electrical supply make it suitable for installation in laboratory utility rooms or pilot plant buildings. The 2.50 MPa discharge pressure is adequate for most laboratory high-pressure applications, while the oil-free certification ensures that nitrogen purity meets the stringent requirements of research-grade experiments and analytical instrumentation.
Materiais e construção
The ZW-2.1/8~25 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 2.50 MPa operating pressure.
Diretrizes de Instalação e Manutenção
Requisitos de fundação e estrutura
The ZW-2.1/8~25 has a dry weight of 2.60 tonnes and a center of gravity approximately 750 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 2.50 MPa.
Projeto de Sistema de Água de Refrigeração
A demanda de água para resfriamento é de aproximadamente 10 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-2.1/8~25 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-2.1/8~25 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 2.50 MPa discharge pressure, the risk of rapid gas release and oxygen displacement is significantly elevated. All ZW-2.1/8~25 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-2.1/8~25 achieves a specific power consumption of approximately 35.71 kW per m³/min of nitrogen at 2.50 MPa discharge pressure from 0.80 MPa inlet. This specific power figure reflects the thermodynamic reality of high-pressure compression from an already elevated inlet pressure. However, the true efficiency advantage of the ZW-2.1/8~25 lies in its ability to accept high-pressure inlet without energy-wasting pressure reduction. When compared to systems that throttle 0.80 MPa nitrogen down to atmospheric pressure before re-compressing to 2.50 MPa, the ZW-2.1/8~25 saves approximately 40–50% 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-2.1/8~25’s variable inlet capability yields approximately 120,000–180,000 kWh of energy savings compared to systems requiring upstream pressure reduction. At $0.08/kWh, this represents $9,600–$14,400 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-2.1/8~25’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-2.1/8~25 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.
- Configurações de áreas perigosas: ATEX Zone 2 and IECEx compliant enclosures for petrochemical installations. Gas detection and automatic ventilation interlocks integrated into the control system.
- 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: Compact IP54-rated sound enclosure reducing noise from 82 dB(A) to 68 dB(A) at 1 meter, suitable for indoor installations in noise-sensitive environments.
- 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: Chemical Plant Nitrogen Recycle System
Cliente: A specialty chemical manufacturer in Thailand operating batch reactors with nitrogen inerting
Desafio: The plant was consuming 8,000 Nm³/day of nitrogen for reactor inerting, with the spent nitrogen vented to atmosphere at 0.60 MPa after passing through the reactors. This once-through approach was costing $180,000/year in nitrogen purchase and represented a significant environmental waste stream. The plant wanted to recover and recycle the nitrogen but needed a compressor capable of accepting the variable outlet pressure from the reactors (0.40–0.80 MPa) and boosting it to 2.00 MPa for re-use in the high-pressure reactor feed system.
Solução: Nós fornecemos um ZW-2.1/8~25 oil-free nitrogen compressor configured on a custom 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, eliminating the need for upstream pressure regulation. A 1 m³ surge vessel was installed upstream to dampen pressure fluctuations from the batch reactor cycle.
Resultados quantificados após 24 meses:
- Nitrogen consumption: Reduzido em 65% (from 8,000 to 2,800 Nm³/day), saving $117,000/year
- Nitrogen vent emissions: Reduzido em 65%, improving environmental compliance score
- Oil contamination in recycled nitrogen: <0.01 mg/m³, ensuring no process contamination
- Compressor availability: 98.5% over 24 months, with only scheduled maintenance downtime
- Período de retorno do investimento: 1,8 anos based on nitrogen cost savings alone
“The ZW-2.1/8~25 has paid for itself in under two years. The variable inlet capability was the key feature that made this project feasible—we didn’t need to modify our reactor vent system or add pressure regulators. Our nitrogen costs have dropped by two-thirds and our environmental footprint has improved dramatically.” — Gerente de Fábrica, Unidade de Produtos Químicos Especiais
Perguntas frequentes e guia de seleção
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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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