Compressor de nitrogênio ZW-5.4/6~20 – Booster de N2 isento de óleo com pressão variável para aplicações industriais flexíveis

Engineered to deliver 5.4 m³/min across a versatile pressure range from 0.60 MPa to 2.00 MPa, the ZW-5.4/6~20 is a two-stage, two-row oil-free piston nitrogen compressor designed for multi-pressure nitrogen distribution, pilot plant operations, and flexible industrial gas systems. Zero oil contamination, compact footprint, and optimized for variable-pressure duty cycles.

Visão geral do produto

O ZW-5.4/6~20 nitrogen compressor represents a uniquely versatile solution within our oil-free piston compressor family, distinguished by its broad operating pressure range that spans from 0.60 MPa to 2.00 MPa at a consistent capacity of 5.4 m³/min. This variable-pressure capability makes the unit exceptionally well-suited for applications where nitrogen demand fluctuates between medium-pressure and high-pressure requirements, or where a single compressor must serve multiple consumers at different pressure levels.

The designation “6~20” in the model number reflects the compressor’s ability to operate across a discharge pressure spectrum equivalent to 0.60–2.00 MPa, achieved through adjustable clearance pocket control and staged unloading mechanisms. This flexibility eliminates the need for multiple compressors or intermediate pressure-reducing stations in facilities with diverse nitrogen pressure requirements, significantly reducing capital expenditure and maintenance complexity.

Like all units in our ZW series, the ZW-5.4/6~20 maintains a caminho de compressão totalmente isento de óleo utilizing self-lubricating PTFE composite piston rings and rider bands. This ensures the nitrogen product stream remains completely free of hydrocarbon contamination, achieving Certificação ISO 8573-1 Classe 0 without any downstream purification equipment. The compact dimensions and modest weight make this unit ideal for pilot plants, R&D facilities, and mobile nitrogen supply systems where space and portability are critical constraints.

Technical Specifications – ZW-5.4/6~20

* Capacity rated at 0.60 MPa inlet pressure. At higher discharge pressures, capacity adjusts proportionally. All specifications per ISO 1217, Annex C. Actual performance varies with site altitude, ambient temperature, and inlet conditions.

Principais características e vantagens de engenharia

1. Variable Pressure Range with Clearance Pocket Control

The ZW-5.4/6~20 incorporates an innovative adjustable clearance pocket system that allows the compressor to operate efficiently across a discharge pressure range from 0.60 MPa to 2.00 MPa without mechanical modification. By adjusting the clearance volume in the high-pressure cylinder, the unit optimizes volumetric efficiency at each pressure setpoint. This eliminates the need for multiple compressors or pressure-reducing valves in facilities with variable nitrogen pressure requirements, reducing both capital expenditure and operating complexity. The pressure adjustment can be performed manually or automated via pneumatic actuators integrated with the control system.

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

The ZW-5.4/6~20 employs a sistema de anel de pistão autolubrificante e cinta de guia constructed from high-performance PTFE composites reinforced with carbon fiber and bronze particulates. This material formulation is specifically engineered for high-pressure nitrogen service, maintaining sealing integrity and low friction coefficients across the full 0.60–2.00 MPa operating range. The rings achieve a coefficient of friction below 0.07 without any external lubrication, ensuring Conteúdo de óleo Classe 0 ISO 8573-1 in the compressed nitrogen stream. For pilot plants and research facilities where nitrogen purity is non-negotiable, this native oil-free certification eliminates downstream filtration costs entirely.

3. Two-Stage Compression for Extended Pressure Ratio

O arquitetura de dois estágios e duas fileiras is essential for managing the high pressure ratios associated with 2.00 MPa discharge pressure. By dividing the compression work between a low-pressure cylinder and a high-pressure cylinder, the unit limits the discharge temperature of each stage to below 160°C, preserving PTFE ring integrity and preventing thermal degradation. An integrated shell-and-tube intercooler removes the heat of compression between stages, improving overall thermodynamic efficiency and extending valve plate service life. At lower discharge pressures (0.60–1.00 MPa), the unit can operate with reduced inter-stage cooling demand, further improving efficiency.

4. Flexible Voltage Configuration for Diverse Installations

The ZW-5.4/6~20 is available with a 132 kW drive motor in 380V, 6kV, or 10kV configurations. The standard 380V option is ideal for laboratory and pilot plant installations with existing low-voltage distribution infrastructure. The 6kV and 10kV options cater to industrial facilities with medium-voltage bus systems, reducing electrical infrastructure costs and improving energy efficiency by eliminating step-down transformers. This voltage flexibility ensures the ZW-5.4/6~20 can be integrated into virtually any electrical environment without costly modifications.

Cenários de aplicação

Pilot Plants & Process Development Facilities

Chemical and pharmaceutical pilot plants frequently require nitrogen at varying pressures depending on the process being tested. The ZW-5.4/6~20 variable-pressure nitrogen compressor serves as a single, flexible nitrogen source that can supply inerting gas at 0.60 MPa for reactor blanketing during one campaign, then adjust to 2.00 MPa for high-pressure catalyst testing during the next campaign. The 5.4 m³/min capacity is well-matched to the scale of pilot plant operations, and the oil-free design ensures no hydrocarbon contamination of sensitive catalysts or reaction products.

Multi-Pressure Industrial Gas Distribution

Industrial facilities with diverse nitrogen consumers—such as tank blanketing at 0.60 MPa, pipeline purging at 1.20 MPa, and emergency vessel inerting at 2.00 MPa—traditionally require multiple compressors or pressure-reducing stations. The ZW-5.4/6~20 eliminates this complexity by providing a single compressor capable of serving all pressure requirements. The adjustable discharge pressure can be changed between shifts or campaigns to match the active process demands, reducing equipment count and simplifying maintenance scheduling.

Mobile Nitrogen Supply & Emergency Response

The compact footprint and modest weight of the ZW-5.4/6~20 make it ideal for mobile nitrogen supply units mounted on road-legal trailers. The variable pressure capability is particularly valuable in emergency response scenarios where nitrogen may be needed at different pressures for pipeline purging, vessel inerting, or fire suppression. The unit can be transported to the site, connected to a nitrogen source (liquid nitrogen vaporizer or small VPSA generator), and quickly adjusted to the required discharge pressure. The oil-free design ensures no contamination of the protected process equipment.

Research & University Laboratories

University research laboratories and national research institutes require high-purity nitrogen for a wide range of experiments, from inert atmosphere glove boxes (0.60 MPa) to high-pressure synthesis reactors (2.00 MPa). The ZW-5.4/6~20’s variable pressure range and oil-free certification make it an ideal central nitrogen supply for multi-disciplinary research facilities. The 5.4 m³/min capacity can simultaneously support multiple high-pressure reactors, several glove box stations, and gas chromatography instruments without compromising purity or pressure stability.

Materiais e construção

The ZW-5.4/6~20 is constructed from materials selected for high-pressure nitrogen compatibility, corrosion resistance, and compact structural integrity:

Todos os componentes que suportam pressão estão em conformidade com ASME BPVC Seção VIII Divisão 1 or Chinese GB 150 standards. Weld joints are subjected to 100% radiographic inspection (RT), and each pressure vessel undergoes hydrostatic testing at 1.5× MAWP for a minimum 30-minute hold period.

Diretrizes de Instalação e Manutenção

Requisitos de Fundação e Espaciais

The ZW-5.4/6~20 weighs 2.40 tonnes and features a compact vertical design with a low center of gravity. A reinforced concrete pad of 4–5 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. 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. The unit’s forklift-compatible base frame allows positioning without overhead crane equipment.

Especificações da água de resfriamento

A demanda de água para resfriamento é de aproximadamente 15 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 installations without reliable municipal water supply, a compact closed-loop cooling tower with a 0.5 m³ buffer tank is recommended. At higher discharge pressures (1.50–2.00 MPa), cooling water flow should be increased by approximately 20% to manage the additional heat of compression.

Intervalos de manutenção

The oil-free design eliminates all oil-related maintenance tasks. There are no oil changes, filter replacements, separator cartridge changes, or oil analysis requirements. The only consumable wear items are the Anéis de pistão e anéis de guia de PTFE, which typically achieve 3,500–5,500 hours at high-pressure operation (1.50–2.00 MPa) and 4,500–6,500 hours at medium-pressure operation (0.60–1.00 MPa).

Certificações de Conformidade e Segurança

The ZW-5.4/6~20 nitrogen compressor meets the following international standards and regulatory requirements:

Análise de desempenho e eficiência

The ZW-5.4/6~20 achieves a specific power consumption of approximately 24.4 kW per m³/min at 2.00 MPa discharge pressure, improving to approximately 18.5 kW/m³/min at 0.60 MPa. While the specific power is higher than larger-capacity models due to reduced scale efficiency, the unit’s variable-pressure capability delivers unique operational flexibility that offsets the marginal efficiency penalty. For comparison, a dedicated high-pressure diaphragm compressor of equivalent capacity would consume 28–35 kW/m³/min, while oil-lubricated screw compressors at 2.00 MPa typically exceed 20 kW/m³/min.

The primary economic advantage of the ZW-5.4/6~20 is the elimination of multiple compressors in facilities with variable pressure requirements. A facility requiring nitrogen at 0.60 MPa, 1.20 MPa, and 2.00 MPa would traditionally need three separate compressors or one compressor plus two pressure-reducing stations. The ZW-5.4/6~20 replaces this entire infrastructure with a single unit, reducing capital expenditure by 40–60% and maintenance complexity by a similar margin. The custo total de propriedade para compressão de nitrogênio in variable-pressure applications is dominated by equipment count and maintenance labor rather than marginal energy efficiency.

The oil-free design further reduces TCO by eliminating oil-related consumables. A typical lubricated compressor of this size and pressure range consumes 80–150 liters of lubricating oil annually, plus filter elements, separator cartridges, and waste oil disposal costs totaling $1,500–$3,000/year. The ZW-5.4/6~20 removes these expenses entirely.

Personalização e capacidades OEM

We provide flexible customization options to adapt the ZW-5.4/6~20 to specific installation constraints and end-user requirements:

• Pacotes montados em skid: Compressor, motor, resfriador e painel de controle pré-montados em uma estrutura de aço com encaixes para empilhadeira e olhais de içamento. Reduz a instalação em campo à conexão elétrica e à ligação da água de refrigeração.
• Unidades móveis em reboque: The ZW-5.4/6~20 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.
• Automated Pressure Control: Optional Siemens LOGO! or S7-1200 PLC with pressure feedback loop, automatically adjusting clearance pocket volume to maintain set discharge pressure within ±0.05 MPa. Remote monitoring via Modbus TCP/IP or OPC-UA.
• 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: Esquemas de pintura personalizados, placas de identificação com a marca e pacotes de documentação localizados para distribuidores de equipamentos a gás e integradores de sistemas.

Configurações personalizadas estão disponíveis em Quantidade mínima de encomenda: 1 unidade. Engineering proposals delivered within 3–5 business days. Standard delivery: 10–12 weeks; expedited delivery within 8 weeks for qualifying orders.

Case Study: Multi-Pressure Pilot Plant Nitrogen Supply

Cliente: A specialty chemical company operating a multi-reactor pilot plant in Germany

Desafio: The pilot plant operated four reactors with different nitrogen pressure requirements: Reactor A (0.60 MPa for inerting), Reactor B (1.20 MPa for catalyst activation), Reactor C (1.60 MPa for high-pressure synthesis), and Reactor D (2.00 MPa for polymerization). The client was maintaining three separate compressors (0.60 MPa, 1.20 MPa, and 2.00 MPa) plus pressure-reducing stations, resulting in high capital costs, complex maintenance scheduling, and frequent cross-contamination issues when switching between reactors.

Solução: Nós fornecemos um ZW-5.4/6~20 oil-free nitrogen compressor with automated clearance pocket control, replacing all three existing compressors. The unit was configured on a compact skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC with pressure feedback control. The PLC automatically adjusts discharge pressure to match the active reactor requirements, switching between setpoints in under 5 minutes.

Resultados após 18 meses:

• Capital equipment: Reduced from 3 compressors to 1, saving €180,000 in initial investment
• Maintenance costs: Reduzido em 58% (from €24,000/year to €10,100/year)
• Floor space: Reduzido em 65% (from 18 m² to 6.3 m²)
• Pureza do nitrogênio: Consistentemente >99,9% with oil content <0.01 mg/m³ across all pressure setpoints
• Reactor switching time: Reduced from 45 minutes to under 5 minutes, improving pilot plant throughput

“The ZW-5.4/6~20 has simplified our nitrogen supply dramatically. We no longer maintain three compressors or worry about pressure-reducing valve failures. The automatic pressure switching is seamless, and our pilot plant operators love the simplicity.” — Process Engineering Manager

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Ready for a Flexible Nitrogen Compression Solution?

Our application engineers are available to evaluate your multi-pressure nitrogen requirements and demonstrate how the ZW-5.4/6~20 can replace multiple compressors with a single, versatile unit. We provide complimentary technical proposals, TCO analyses, and pilot plant integration guidance within 48 hours.

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