3ZW-9.5/30 kvävgaskompressor – Trestegs oljefri N2-booster för 3,00 MPa högtrycksprocesstillämpningar

3ZW-9.5/30 är konstruerad för att leverera 9,5 m³/min vid 3,00 MPa utloppstryck och är en trestegs, treradig oljefri kolvkompressor med kväve, avsedd för ultrahögtrycksinsprutning av kväve, gasflaskpåfyllningsstationer och krävande kemiska processapplikationer. Noll oljekontaminering, flerstegs termodynamisk optimering och byggd för kontinuerlig drift vid extremt tryck.

Produktöversikt

De 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 och en exceptionell 3,00 MPa utloppstryck, 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 ISO 8573-1 Klass 0-certifiering 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.

Kompressorn använder en three-stage, three-row (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 timmar enligt standardiserade underhållsprotokoll.

Technical Specifications – 3ZW-9.5/30

* Alla specifikationer är klassade vid standardreferensförhållanden (ISO 1217, bilaga C). Faktisk prestanda kan variera beroende på platsens höjd över havet, omgivningstemperatur och inloppsförhållanden.

Viktiga funktioner och tekniska fördelar

1. Three-Stage Compression for Ultra-High Pressure

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 självsmörjande kolvring och ryttarbandsenhet 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 ISO 8573-1 klass 0-certifiering direkt, 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

Huvudramen är gjuten av GG25 grått gjutjärn (equivalent to ASTM A48 Class 30B) with reinforced wall sections and integral cooling water passages. The treradigt motstående cylindrarrangemang 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.

Applikationsscenarier

Högtrycks-kvävgasflaskpåfyllningsstationer

The 3ZW-9.5/30 is purpose-built for kvävgasflaskpåfyllningsoperationer 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.

Chemical Synthesis & High-Pressure Reactor Inerting

In chemical process plants, the 3ZW-9.5/30 nitrogen compressor provides ultra-high-pressure nitrogen for högtrycksreaktorinerting, konservering av katalysatorbädd och extraktionsprocesser för superkritiska vätskor. 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.

Material och konstruktion

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

Alla tryckbärande komponenter är konstruerade och tillverkade i strikt enlighet med ASME BPVC avsnitt VIII division 1 eller kinesiska GB 150-standarder. Varje svetsfog genomgår 100% radiografisk inspektion (RT) enligt ASME avsnitt V, artikel 2, och varje färdigställt tryckkärl utsätts för ett hydrostatiskt tryckprov vid 1,5 gånger det maximalt tillåtna arbetstrycket (MAWP) under en minsta hållperiod på 30 minuter. Högtrycksrörsystem är tillverkade av sömlös SS316 med ANSI klass 900 flänsanslutningar för att säkerställa läckagetäthet vid 3,00 MPa driftstryck.

Installations- och underhållsriktlinjer

Grund- och strukturkrav

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 armerad betongblock på 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.

Design av kylvattensystem

Kylvattenbehovet är ungefär 22 m³/h 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.

Schema för förebyggande underhåll

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 PTFE-kolvringar och ryttarband, 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.

Efterlevnads- och säkerhetscertifieringar

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

Prestanda- och effektivitetsanalys

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 total ägandekostnad för ultrahögtryckskvävgaskompression 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.

Anpassning och OEM-funktioner

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

• Nyckelfärdiga paket för medarmontering: 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%.
• Konfigurationer för farliga områden: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks with emergency isolation valves.
• Avancerad processkontroll: 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.
• Miljöskydd: C5-M marinbeläggningar för kustinstallationer; tropiska elektriska komponenter för 55 °C omgivningstemperatur; IP54-klassade akustiska kapslingar som minskar buller från 85 dB(A) till 72 dB(A) på 1 meters avstånd.
• OEM och privat etikett: Anpassade färger, namnskyltar med varumärken och lokaliserad dokumentation för distributörer av gasutrustning och systemintegratörer.

Anpassade konfigurationer är tillgängliga från MOQ 1 enhet. 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

Utmaning: 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.

Lösning: Vi levererade en 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.

Kvantifierade resultat efter 18 månader:

• Kvävgasoljehalt i fyllda cylindrar: Reduced from 2.0 mg/m³ to <0.01 mg/m³, uppnår ISO 8573-1 klass 0
• Byte av aktivt kolbädd: Eliminerad helt, vilket sparar 18 000 kr/år på förbrukningsvaror
• Diaphragm compressor efficiency: Improved by 15%, reducing its power consumption by 22 kW
• Customer complaints and returns: Noll since commissioning, with contracts renewed for 3 additional years
• Återbetalningsperiod: 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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