ZW-13/30 நைட்ரஜன் அமுக்கி – 3.00 MPa உயர் அழுத்த செயல்முறைப் பயன்பாடுகளுக்கான நடுத்தர கொள்ளளவு எண்ணெய் இல்லாத N2 பூஸ்டர்

Engineered to deliver 13 m³/min at 3.00 MPa discharge pressure, the ZW-13/30 is a two-stage, three-row oil-free piston nitrogen compressor designed for demanding high-pressure nitrogen injection, gas cylinder filling stations, and critical petrochemical process applications. Zero oil contamination, robust three-row force balance, and optimized for continuous-duty operation at elevated pressure.

தயாரிப்பு கண்ணோட்டம்

தி ZW-13/30 nitrogen compressor represents a powerful mid-range solution within our oil-free piston compressor family, engineered for applications where both substantial flow capacity and high discharge pressure are simultaneously required. With a rated capacity of 13 m³/min and a discharge pressure of 3.00 MPa, this unit occupies a critical position in the high-pressure nitrogen compressor market, bridging the gap between small laboratory-scale units and massive industrial boosters.

What distinguishes the ZW-13/30 from conventional alternatives is its fully oil-free compression pathway utilizing self-lubricating PTFE composite piston rings and rider bands. This design philosophy eliminates any possibility of hydrocarbon contamination in the nitrogen product stream, achieving ISO 8573-1 வகுப்பு 0 சான்றிதழ் natively. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is substantially magnified compared to low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for food-grade, pharmaceutical, and electronics-grade nitrogen service.

The compressor architecture employs a two-stage, three-row (二列三级) configuration that is essential for managing the extreme pressure ratio required to achieve 3.00 MPa from typical inlet conditions. The three-row opposed-cylinder arrangement provides superior force balance compared to two-row designs, reducing vibration transmission and permitting installation on lighter foundations. Each compression stage is equipped with an independent high-efficiency intercooler, ensuring gas temperatures remain within safe operating envelopes even during sustained maximum-load operation. The robust cast-iron frame and dynamically balanced forged steel crankshaft are rated for a minimum service life of 120,000 மணிநேரம் நிலையான பராமரிப்பு நெறிமுறைகளின் கீழ்.

Technical Specifications – ZW-13/30

* அனைத்து விவரக்குறிப்புகளும் தரநிலை குறிப்பு நிபந்தனைகளின் (ISO 1217, இணைப்பு C) அடிப்படையில் மதிப்பிடப்பட்டுள்ளன. உண்மையான செயல்திறன், தளத்தின் உயரம், சுற்றுப்புற வெப்பநிலை மற்றும் உள்ளீட்டு நிலைமைகள் ஆகியவற்றைப் பொறுத்து மாறுபடலாம்.

முக்கிய அம்சங்கள் மற்றும் பொறியியல் நன்மைகள்

1. Three-Row Opposed-Cylinder Force Balance

The ZW-13/30 employs a unique three-row opposed-cylinder arrangement (二列三级) that provides exceptional first-order and second-order force cancellation. By distributing the compression work across three cylinders arranged in an opposed configuration, the compressor achieves near-perfect inertial force balance, reducing vibration transmission to the foundation by over 90% compared to single-row designs. This mechanical advantage is particularly critical for high-pressure compressors where the peak gas forces on the pistons are substantially higher than in low-pressure applications. The three-row design permits installation on a lighter reinforced concrete inertia block (minimum 10 tonnes versus 15+ tonnes for equivalent single-row units), significantly reducing civil engineering costs and simplifying retrofit installations in existing process plants.

2. High-Pressure Oil-Free PTFE Composite Sealing

The ZW-13/30 utilizes a proprietary சுய உயவு பிஸ்டன் வளையம் மற்றும் ரைடர் பேண்ட் அசெம்பிளி manufactured from high-density PTFE composites specifically formulated for high-pressure service. These rings are reinforced with glass fiber and bronze particulates to achieve a coefficient of friction below 0.05 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 far more concentrated and difficult to remove. The ZW-13/30’s native oil-free design achieves ISO 8573-1 வகுப்பு 0 சான்றிதழ் without any downstream filtration, eliminating both the capital cost and the energy penalty of oil-removal equipment. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, ensuring reliable sealing integrity under the extreme thermal stress of high-pressure compression.

3. Two-Stage Thermodynamic Optimization for Extreme Pressure Ratios

தி two-stage compression architecture of the ZW-13/30 is thermodynamically essential for achieving the 3.00 MPa discharge pressure target from typical inlet pressures of 0.05–0.10 MPa. The overall pressure ratio of approximately 30:1 to 60:1 is divided between a low-pressure cylinder group and a high-pressure cylinder group, with each stage operating at a manageable pressure ratio. A high-efficiency shell-and-tube intercooler between stages removes the substantial heat of compression, maintaining discharge temperatures below 160°C and preventing thermal degradation of the PTFE sealing elements. Without staged compression, the discharge temperature would exceed 250°C, far beyond the safe operating limit of any oil-free sealing material. The inter-stage cooling is therefore not merely an efficiency enhancement but a fundamental requirement for reliable high-pressure oil-free operation.

4. Standard 380V Industrial Motor Drive with High Efficiency

The ZW-13/30 is driven by a 160 kW, 380V, 50Hz three-phase induction motor 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. For sites with 6kV or 10kV bus systems, an optional motor with integrated step-down transformer can be supplied on a common skid, providing seamless integration into any electrical infrastructure.

பயன்பாட்டு சூழ்நிலைகள்

உயர் அழுத்த நைட்ரஜன் சிலிண்டர் நிரப்பும் நிலையங்கள்

The ZW-13/30 is ideally suited for industrial nitrogen cylinder filling operations where high-pressure gas must be compressed into standard industrial cylinders at 15–20 MPa filling pressure. While the compressor’s 3.00 MPa discharge pressure does not reach cylinder filling pressure directly, it serves as a highly efficient intermediate booster that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. The 13 m³/min capacity can supply multiple filling manifolds simultaneously, making the ZW-13/30 suitable for commercial gas filling stations serving industrial, medical, and specialty gas markets. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the cylinders and delivered to end-users, potentially compromising their processes and creating liability exposure.

Petrochemical High-Pressure Process Nitrogen

In petrochemical and refinery operations, the ZW-13/30 high-pressure nitrogen compressor provides nitrogen for reactor catalyst preservation, emergency injection into high-pressure vessels, pipeline pressure testing, and hydrostatic testing of process equipment. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into process vessels operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during startup, shutdown, and upset conditions. The continuous-duty rating ensures uninterrupted nitrogen availability during extended turnaround campaigns. The oil-free certification is mandatory for petrochemical applications where nitrogen contacts catalyst beds or enters process streams that must remain completely hydrocarbon-free.

Gas Liquefaction & Cryogenic Storage Booster

In nitrogen liquefaction plants and cryogenic storage facilities, the ZW-13/30 compresses nitrogen from the liquefier vaporizer or storage tank boil-off 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, and supplying high-pressure consumers in the process plant. The 13 m³/min capacity matches the output of small to medium-scale liquefaction plants, making the ZW-13/30 an ideal integrated booster for on-site nitrogen liquefaction systems. The oil-free design prevents contamination of the cryogenic equipment and ensures the purity of liquid nitrogen product.

Pharmaceutical & Food-Grade High-Pressure Nitrogen

Pharmaceutical manufacturing and large-scale food processing facilities require high-purity nitrogen at elevated pressure for sterile filtration, spray drying, aseptic filling, and high-pressure packaging applications. The ZW-13/30’s oil-free certification ensures compliance with FDA 21 CFR 211.72 and EU GMP Annex 1. The 3.00 MPa discharge pressure provides adequate head to drive nitrogen through sterile filtration systems, spray dryers, and high-pressure packaging equipment. The 13 m³/min capacity can simultaneously supply multiple pharmaceutical process lines or food packaging stations within a single manufacturing facility, making the ZW-13/30 a versatile central nitrogen supply solution.

பொருள் மற்றும் கட்டுமானம்

The ZW-13/30 is constructed from premium materials selected for high-pressure nitrogen compatibility, thermal resistance, and extended operational life:

அனைத்து அழுத்தம் தாங்கும் கூறுகளும் கண்டிப்பாக விதிமுறைகளுக்கு இணங்க வடிவமைக்கப்பட்டு தயாரிக்கப்படுகின்றன. ASME BPVC பிரிவு VIII பிரிவு 1 அல்லது சீன GB 150 தரநிலைகள். ஒவ்வொரு பற்றவைப்பு இணைப்பும் ASME பிரிவு V, கட்டுரை 2-இன் படி 100% கதிரியக்க ஆய்வுக்கு (RT) உட்படுத்தப்படுகிறது, மேலும் முடிக்கப்பட்ட ஒவ்வொரு அழுத்தக் கலனும், அதிகபட்ச அனுமதிக்கப்பட்ட இயக்க அழுத்தத்தை (MAWP) விட 1.5 மடங்கு அழுத்தத்தில், குறைந்தபட்சம் 30 நிமிடத் தக்கவைப்புக் காலத்திற்கு ஒரு ஹைட்ரோஸ்டேடிக் அழுத்தச் சோதனைக்கு உட்படுத்தப்படுகிறது. உயர் அழுத்தக் குழாய் அமைப்புகள், 3.00 MPa இயக்க அழுத்தத்தில் கசிவு-இறுக்கமான ஒருமைப்பாட்டை உறுதி செய்வதற்காக, ANSI வகுப்பு 900 ஃபிளேன்ஜ்டு இணைப்புகளுடன் தடையற்ற SS316-இலிருந்து தயாரிக்கப்படுகின்றன.

நிறுவல் மற்றும் பராமரிப்பு வழிகாட்டுதல்கள்

அடித்தளம் மற்றும் கட்டமைப்புத் தேவைகள்

The ZW-13/30 has a dry weight of 6.00 tonnes and a center of gravity approximately 900 mm above the baseplate. Thanks to the three-row opposed-cylinder design, unbalanced forces are minimal despite the high-pressure operation, permitting installation on a reinforced concrete inertia block of 10–12 tonnes. The block should be mounted on elastomeric vibration isolators (natural frequency 6–8 Hz). Minimum clearance requirements: 1.5 m on the non-drive side for valve access, 1.2 m on the drive side for motor maintenance, and 2.0 m overhead for crane access during major overhauls. Special attention must be paid to the high-pressure discharge piping, which must be properly supported, anchored, and stress-relieved to prevent vibration-induced fatigue at 3.00 MPa.

குளிரூட்டும் நீர் அமைப்பு வடிவமைப்பு

குளிரூட்டும் நீரின் தேவை தோராயமாக 28 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets, intercooler, and aftercooler in parallel branches. Given the extreme pressure ratio, the intercooler is absolutely critical for thermal management and must receive priority 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 and chemical treatment is strongly recommended for all installations to ensure consistent water quality.

தடுப்பு பராமரிப்பு அட்டவணை

The oil-free design of the ZW-13/30 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 பிஸ்டன் வளையங்கள் மற்றும் ரைடர் பேண்டுகள், which typically achieve 3,000–5,000 hours of service life under clean nitrogen conditions at high pressure. The high-pressure valve plates may require more frequent inspection than low-pressure equivalents due to the increased mechanical stress at 3.00 MPa, but the overall maintenance burden remains significantly lower than oil-lubricated systems.

இணக்கம் மற்றும் பாதுகாப்புச் சான்றிதழ்கள்

The ZW-13/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

செயல்திறன் மற்றும் திறன் பகுப்பாய்வு

The ZW-13/30 achieves a specific power consumption of approximately 12.31 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, where the work required increases substantially with pressure ratio. Within the high-pressure oil-free piston compressor segment (discharge pressure >2.50 MPa), this efficiency is competitive and often superior to diaphragm compressors, which are the primary alternative for oil-free high-pressure service. For comparison, oil-lubricated reciprocating compressors in similar ultra-high-pressure applications typically consume 13.0–15.0 kW/m³/min, while diaphragm compressors may exceed 18 kW/m³/min.

Over a standard 8,000-hour annual operating schedule, the ZW-13/30’s efficiency advantage versus less efficient alternatives yields approximately 60,000–140,000 kWh of annual energy savings. At $0.08/kWh, this represents $4,800–$11,200 in direct electricity cost reduction per year. However, the primary economic driver for ZW-13/30 selection is typically the elimination of oil-related consumables and the avoidance of downstream oil-removal equipment that would be mandatory with lubricated alternatives. At 3.00 MPa, the partial pressure of oil vapor is approximately 15 times higher than at 0.30 MPa, making downstream oil-filtration systems exponentially more expensive and less effective. The அதி உயர் அழுத்த நைட்ரஜன் அமுக்கத்திற்கான மொத்த உரிமையாளர் செலவு is reduced by an estimated 25–35% over a 10-year operational life when oil-free operation is compared to lubricated systems with full downstream purification.

The absence of oil in the compression path is particularly critical at 3.00 MPa because oil contamination becomes highly concentrated and virtually impossible to remove to the levels required by food-grade, pharmaceutical, and semiconductor applications. The ZW-13/30’s native oil-free design eliminates this challenge entirely, providing guaranteed product purity without the complexity and cost of downstream purification trains.

தனிப்பயனாக்கம் மற்றும் OEM திறன்கள்

We offer comprehensive customization options to adapt the ZW-13/30 to specific site conditions, integration requirements, and end-user specifications:

• சறுக்குப்பலகை பொருத்தப்பட்ட முழுமையான தொகுப்புகள்: Pre-assembled compressor, motor, intercooler, aftercooler, high-pressure discharge piping, 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 and risk.
• அபாயகரமான பகுதி உள்ளமைவுகள்: ATEX Zone 2 and IECEx compliant motor and electrical enclosures for petrochemical installations. Integrated gas detection and automatic ventilation interlocks incorporated into the control system.
• மேம்பட்ட செயல்முறைக் கட்டுப்பாடு: 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. High-pressure safety interlocks including automatic unload on overpressure, emergency isolation valves, and redundant pressure monitoring.
• சுற்றுச்சூழல் பாதுகாப்பு: C5-M marine-grade coating systems for coastal installations; tropicalized electrical components for ambient temperatures up to 55°C; and IP54-rated acoustic enclosures reducing noise emission from 85 dB(A) to 72 dB(A) at 1 meter.
• OEM மற்றும் பிரைவேட் லேபிள்: Custom paint colors, branded nameplates, and localized documentation packages for gas equipment distributors and system integrators. Technical manuals and maintenance procedures available in multiple languages.

தனிப்பயன் உள்ளமைவுகள் இங்கிருந்து கிடைக்கின்றன குறைந்தபட்ச ஆர்டர் அளவு 1 அலகு. Engineering review and proposal generation typically require 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 Filling Station Upgrade

வாடிக்கையாளர்: A major industrial gas supplier in Malaysia operating a nitrogen cylinder filling station serving manufacturing, medical, and food processing customers

சவால்: The client’s existing oil-lubricated high-pressure compressor (European brand, 14 years in service) was experiencing progressive oil carryover into the nitrogen product stream. Oil contamination levels reached 2.2 mg/m³, far exceeding the 0.1 mg/m³ specification required by pharmaceutical and food-grade customers. The oil was also degrading the activated carbon purification beds in the filling manifold, requiring replacement every 5 months instead of the designed 18-month interval. Customer complaints were increasing, and regulatory inspections were becoming more frequent and demanding.

தீர்வு: நாங்கள் வழங்கினோம் ZW-13/30 oil-free nitrogen compressor as the primary intermediate booster, configured on a custom skid with integrated intercooler, aftercooler, and a Siemens S7-1200 PLC control panel. The 3.00 MPa discharge pressure fed a downstream high-pressure filling compressor, reducing the overall compression ratio required of the filling stage. The oil-free design eliminated the need for activated carbon purification beds entirely. A 3 m³ surge vessel was installed upstream to buffer demand fluctuations from the filling manifold.

Quantified Results After 24 Months:

• Nitrogen oil content: Reduced from 2.2 mg/m³ to <0.01 mg/m³ISO 8573-1 வகுப்பு 0 சான்றிதழைப் பெறுதல்
• செயல்படுத்தப்பட்ட கார்பன் படுக்கை மாற்றுதல்: முற்றிலுமாக அகற்றப்பட்டது, saving $12,000/year in consumables
• Customer complaints: பூஜ்ஜியம் since commissioning, with five new pharmaceutical contracts won
• Filling compressor maintenance: Reduced by 35% due to lower inlet pressure ratio
• Regulatory inspection results: Passed with zero findings in two consecutive audits
• முதலீட்டைத் திரும்பப் பெறும் காலம்: 2.3 ஆண்டுகள் based on cost savings and new contract revenue

“The ZW-13/30 has transformed our filling station from a quality risk into a competitive advantage. We now guarantee ISO 8573-1 Class 0 nitrogen to every customer, and we’ve won contracts that we couldn’t even bid on before. The oil-free design has eliminated our biggest operational headache and our customers have noticed the difference immediately.” — Operations Director, Industrial Gas Supplier

அடிக்கடி கேட்கப்படும் கேள்விகள் மற்றும் தேர்வு வழிகாட்டி

தொடர்புடைய தயாரிப்புகள் மற்றும் தீர்வுகள்

எங்கள் விரிவான கண்ணோட்டத்திற்கு தொழில்துறை நைட்ரஜன் அமுக்கி எண்ணெய் இல்லா ஆக்சிஜன் அமுக்கிகள், ஹைட்ரஜன் அமுக்கிகள், கார்பன் டை ஆக்சைடு அமுக்கிகள் மற்றும் பிரத்யேகமாக வடிவமைக்கப்பட்ட சிறப்பு வாயுத் தீர்வுகள் உள்ளிட்ட எங்கள் தயாரிப்புத் தொகுப்பைப் பற்றி அறிய, எங்கள் பயன்பாட்டுப் பொறியியல் குழுவைத் தொடர்பு கொள்ளவும் அல்லது எங்கள் இணையதள தயாரிப்புப் பட்டியலைப் பார்வையிடவும்.

Ready to Upgrade Your High-Pressure Nitrogen System?

உங்கள் நைட்ரஜன் பாய்வுத் தேவைகள், உறிஞ்சும் நிலைமைகள், வெளியேற்ற அழுத்த இலக்குகள் மற்றும் ஒருங்கிணைப்புக் கட்டுப்பாடுகளை மதிப்பிடுவதற்கு எங்கள் பயன்பாட்டுப் பொறியாளர்கள் தயாராக உள்ளனர். உங்கள் விசாரணையைப் பெற்ற 48 மணி நேரத்திற்குள், நாங்கள் இலவச தொழில்நுட்ப முன்மொழிவுகள், அடித்தள தளவமைப்பு வரைபடங்கள், குழாய் மற்றும் கருவியமைப்பு வரைபடங்கள் (P&IDs) மற்றும் விரிவான மொத்த உரிமையாளர் செலவு (TCO) பகுப்பாய்வுகளை வழங்குகிறோம்.

மின்னஞ்சல்: [email protected] 24 மணி நேரத்திற்குள் பதில் அளிக்கப்படும்