3ZW-6/30 Azot Kompresörü – 3,00 MPa Yüksek Basınçlı Proses Uygulamaları için Üç Kademeli Yağsız N2 Takviye Edici

3,00 MPa deşarj basıncında 6 m³/dak debi sağlamak üzere tasarlanan 3ZW-6/30, ultra yüksek basınçlı azot enjeksiyonu, gaz tüpü dolum istasyonları ve zorlu kimyasal sentez süreçleri için tasarlanmış üç kademeli, üç sıralı yağsız pistonlu azot kompresörüdür. Sıfır yağ kirliliği, sağlam çok kademeli mimari ve aşırı basınçta sürekli çalışma için optimize edilmiştir.

Ürün Genel Bakışı

O 3ZW-6/30 nitrogen compressor represents the pinnacle of our oil-free piston compressor technology, engineered specifically for applications that demand both substantial flow capacity and ultra-high discharge pressure. With a rated capacity of 6 m³/min ve olağanüstü 3,00 MPa deşarj basıncı, this unit occupies the high-pressure segment of our industrial nitrogen compressor portfolio, serving the most demanding process applications in the chemical, petrochemical, and gas distribution industries.

The “3ZW” designation signifies the üç aşamalı, üç sıralı (三列三级) architecture that is fundamental to achieving the 3.00 MPa discharge pressure while maintaining thermal stability and mechanical reliability. Each of the three compression stages operates at a moderate pressure ratio, with dedicated intercoolers between stages removing the heat of compression. This multi-staged approach is essential because the overall pressure ratio from atmospheric inlet to 3.00 MPa exceeds the safe operating limits of single-stage or two-stage designs, both in terms of discharge temperature and mechanical stress on the pistons and crankshaft.

What distinguishes the 3ZW-6/30 from conventional alternatives is its tamamen yağsız sıkıştırma yolu. The piston rings and rider bands are precision-machined from advanced self-lubricating PTFE composite materials that operate without any hydrocarbon lubricants. At 3.00 MPa discharge pressure, the risk of oil vapor carryover is exponentially higher than at low-pressure applications, making the oil-free design not merely advantageous but absolutely mandatory for any application requiring high-purity nitrogen. The unit achieves ISO 8573-1 Sınıf 0 sertifikası natively, without downstream oil-filtration equipment.

Technical Specifications – 3ZW-6/30

* Tüm özellikler standart referans koşullarında (ISO 1217, Ek C) değerlendirilmiştir. Gerçek performans, saha rakımına, ortam sıcaklığına ve giriş koşullarına bağlı olarak değişebilir.

Başlıca Özellikler ve Mühendislik Avantajları

1. Ultra Yüksek Basınç için Üç Aşamalı Sıkıştırma

O three-stage, three-row architecture of the 3ZW-6/30 is the engineering foundation that makes 3.00 MPa discharge pressure achievable with oil-free piston technology. The overall pressure ratio of approximately 30:1 to 60:1 (from atmospheric inlet) is divided across three compression cylinders, with each stage operating at a pressure ratio of approximately 3:1 to 4:1. This staged approach is thermodynamically essential because single-stage compression to 3.00 MPa would produce discharge temperatures exceeding 300°C, far beyond the safe operating limit of PTFE sealing materials. Between each stage, a dedicated high-efficiency shell-and-tube intercooler removes the heat of compression, maintaining discharge temperatures below 155°C at all stages. This thermal management preserves PTFE ring integrity and extends valve plate life by approximately 50% compared to two-stage designs attempting equivalent pressure ratios.

2. Advanced High-Pressure Oil-Free PTFE Sealing System

The 3ZW-6/30 employs a proprietary kendinden yağlamalı piston halkası ve tahrik bandı tertibatı manufactured from ultra-high-performance PTFE composites specifically formulated for 3.00 MPa service. These rings are reinforced with glass fiber, bronze particulates, and molybdenum disulfide 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 exponentially more severe and more difficult to remove downstream. The 3ZW-6/30’s native oil-free design achieves ISO 8573-1 Sınıf 0 sertifikası without any downstream filtration, coalescing, or adsorption equipment. The PTFE formulation is rated for continuous operation at temperatures up to 185°C, with a safety margin that accommodates transient temperature excursions during startup and load changes.

3. Three-Row Opposed-Cylinder Force Balance

Ana gövde döküm yöntemiyle üretilmiştir. GG25 gri dökme demir with reinforced wall sections and integral cooling water passages. The üç sıralı karşılıklı silindir düzenlemesi provides superior force balance compared to single-row or two-row designs, with first-order and second-order inertial forces largely self-canceling. 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 configuration reduces the unbalanced forces transmitted to the foundation by over 85% compared to single-row designs, permitting installation on a lighter reinforced concrete inertia block (minimum 5 tonnes) and reducing the risk of vibration-induced fatigue in connected piping systems. The compact dimensions—1845 × 1660 × 2360 mm—are remarkable for a three-stage compressor of this pressure class, achieved through a vertically stacked cylinder arrangement that minimizes the machine’s footprint.

4. Standart 380V Endüstriyel Motor Sürücüsü

The 3ZW-6/30 is driven by a 75 kW, 380V, 50Hz üç fazlı indüksiyon motoru 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 is particularly valuable for the 3ZW-6/30 because its moderate power requirement (75 kW) does not justify the complexity and cost of medium-voltage infrastructure. The motor is directly coupled to the crankshaft through a flexible disc coupling, eliminating the maintenance burden and efficiency losses associated with belt or gearbox drives.

Uygulama Senaryoları

Ultra-High-Pressure Nitrogen Cylinder Filling

The 3ZW-6/30 is the ideal primary booster for nitrogen cylinder filling stations serving industrial, medical, and specialty gas markets. While the compressor’s 3.00 MPa discharge pressure does not reach the 15–20 MPa required for direct cylinder filling, it serves as a highly efficient intermediate stage that dramatically reduces the compression ratio required of downstream high-pressure filling compressors. In a typical filling station configuration, the 3ZW-6/30 boosts nitrogen from 0.05–0.10 MPa to 3.00 MPa, after which a compact high-pressure diaphragm or piston compressor completes the filling to 20 MPa. This staged approach improves overall system efficiency by 25–35% compared to single-stage high-pressure compression from atmospheric inlet. The oil-free design is mandatory for cylinder filling because any oil contamination would be trapped in the filled cylinders and delivered to end-users, potentially compromising their processes and exposing the filling station to liability.

Kimyasal Sentez ve Yüksek Basınçlı Reaktör İnertleştirme

Kimyasal işlem tesislerinde, 3ZW-6/30 nitrogen compressor ultra yüksek basınçlı nitrojen sağlar high-pressure reactor inerting, catalyst bed preservation, and emergency depressurization of process vessels. The 3.00 MPa discharge pressure is sufficient to inject nitrogen into reactors operating at pressures up to 2.5 MPa, maintaining positive inert gas blankets during all phases of operation. The three-stage compression ensures that the nitrogen remains thermally stable and free of oil contamination, which is critical in chemical synthesis where even trace contaminants can poison catalysts, initiate unwanted side reactions, or compromise product purity. The 6 m³/min capacity can serve multiple high-pressure reactors simultaneously through a centralized nitrogen header.

Gas Liquefaction & Cryogenic Storage Pressure Maintenance

In nitrogen liquefaction plants and cryogenic storage facilities, the 3ZW-6/30 serves as a high-pressure booster that compresses nitrogen vapor from storage tanks or recondensers to the pressure required for distribution or further processing. The 3.00 MPa discharge pressure is adequate for driving nitrogen through heat exchangers, recondensers, and distribution networks in small to medium liquefaction plants. The oil-free design is essential because any oil contamination in the high-pressure nitrogen would be carried into the cryogenic system, where it would freeze and block heat exchanger passages, causing operational failures and costly maintenance. The three-stage compression with intercooling ensures that the nitrogen remains at manageable temperatures throughout the compression process, preventing thermal damage to downstream cryogenic equipment.

Oil & Gas Well Nitrogen Injection

In oil and gas production operations, high-pressure nitrogen is injected into wells for enhanced oil recovery (EOR), well stimulation, and gas lift operations. The 3ZW-6/30’s 3.00 MPa discharge pressure is sufficient for many shallow to medium-depth well applications, where nitrogen is used to displace oil, reduce reservoir pressure, or lift production fluids to the surface. The oil-free design prevents hydrocarbon contamination of the reservoir, which could alter formation permeability and reduce oil recovery efficiency. The 6 m³/min capacity can support continuous nitrogen injection for extended well stimulation campaigns or intermittent gas lift operations for multiple wells.

Malzeme ve İnşaat

The 3ZW-6/30 is constructed from premium materials selected for ultra-high-pressure nitrogen compatibility, thermal resistance, and extended operational life:

Basınç taşıyan tüm bileşenler, aşağıdakilere sıkı sıkıya uygun olarak tasarlanır ve üretilir: ASME BPVC Bölüm VIII Bölüm 1 veya Çin GB 150 standartlarına uygundur. Her kaynak bağlantısı, ASME Bölüm V, Madde 2 uyarınca 100% radyografik muayeneden (RT) geçirilir ve tamamlanan her basınçlı kap, izin verilen maksimum çalışma basıncının (MAWP) 1,5 katı basınçta en az 30 dakika süreyle hidrostatik basınç testine tabi tutulur. Yüksek basınçlı boru sistemleri, 3,00 MPa çalışma basıncında sızdırmazlık sağlamak için ANSI Sınıf 900 flanşlı bağlantılara sahip dikişsiz SS316 malzemeden imal edilir.

Kurulum ve Bakım Kılavuzu

Temel ve Yapısal Gereksinimler

The 3ZW-6/30 has a dry weight of 3.00 tonnes and a center of gravity approximately 800 mm above the baseplate. Thanks to the three-row opposed-cylinder design, unbalanced forces are minimal despite the ultra-high-pressure operation, permitting installation on a 5-6 tonluk takviyeli beton atalet bloğu. 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. Special attention must be paid to the high-pressure discharge piping, which must be properly supported with spring hangers and anchored to prevent vibration-induced fatigue at 3.00 MPa. All high-pressure connections must be verified with ultrasonic testing after installation.

Soğutma Suyu Sistemi Tasarımı

Soğutma suyu ihtiyacı yaklaşık olarak 15 m³/h at an inlet temperature not exceeding 32°C. The water distribution circuit supplies the cylinder jackets and two intercoolers in parallel branches. Given the three-stage compression and high pressure ratio, the intercoolers are absolutely critical for thermal management 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 and chemical treatment is strongly recommended for all installations to ensure consistent water quality and prevent scale formation in the intercoolers.

Önleyici Bakım Programı

The oil-free design of the 3ZW-6/30 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 piston halkaları ve sürücü bantları, which typically achieve 2,500–4,000 hours of service life under clean nitrogen conditions at ultra-high pressure. The high-pressure valve plates (particularly on the third stage) may require more frequent inspection than low-pressure equivalents due to the increased mechanical stress, but the overall maintenance burden remains significantly lower than oil-lubricated systems of equivalent pressure capability.

Uyumluluk ve Güvenlik Sertifikaları

The 3ZW-6/30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

Performans ve Verimlilik Analizi

The 3ZW-6/30 achieves a specific power consumption of approximately 12.50 kW per m³/min of nitrogen delivered at 3.00 MPa discharge pressure from atmospheric inlet. This specific power figure reflects the thermodynamic reality of ultra-high-pressure compression, where the work required increases substantially with pressure ratio. Within the ultra-high-pressure oil-free piston 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, 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 3ZW-6/30’s efficiency advantage versus less efficient alternatives yields approximately 72,000–144,000 kWh of annual energy savings. At $0.08/kWh, this represents $5,760–$11,520 in direct electricity cost reduction per year. However, the primary economic justification for the 3ZW-6/30 is typically the Petrol ile ilgili sarf malzemelerinin ortadan kaldırılması ve petrol çıkarma ekipmanlarından kaçınılması that would be mandatory with lubricated alternatives at this pressure level. The ultra yüksek basınçlı nitrojen sıkıştırmasının toplam sahip olma maliyeti is reduced by an estimated 30–45% 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 valuable at ultra-high pressure because oil contamination becomes exponentially more concentrated and more difficult to remove as pressure increases. At 3.00 MPa, the partial pressure of oil vapor would be approximately 15 times higher than at 0.30 MPa, making downstream oil-filtration systems virtually ineffective and prohibitively expensive. The 3ZW-6/30’s native oil-free design eliminates this challenge entirely, ensuring that nitrogen purity is maintained regardless of operating pressure.

Özelleştirme ve OEM Yetenekleri

We offer comprehensive customization options to adapt the 3ZW-6/30 to specific site conditions, integration requirements, and end-user specifications:

• Kızaklı Montajlı Anahtar Teslim Paketler: Pre-assembled compressor, motor, three intercoolers, 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 by 70%.
• Tehlikeli Alan Yapılandırmaları: Petrokimya tesisleri için ATEX Bölge 2 ve IECEx uyumlu motor ve elektrik muhafazaları. Entegre gaz algılama, otomatik havalandırma kilitlemeleri ve patlamaya dayanıklı ölçüm cihazları.
• Gelişmiş Proses Kontrolü: 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-by-stage pressure monitoring and alarm systems. High-pressure safety interlocks including automatic unload on overpressure and emergency isolation valves on all stages.
• Çevre Koruma: Kıyı tesisatları için C5-M denizcilik sınıfı kaplamalar; 55°C ortam sıcaklığı için tropikleştirilmiş elektrik bileşenleri; 1 metrede gürültüyü 85 dB(A)'dan 72 dB(A)'ya düşüren IP54 dereceli akustik muhafazalar.
• OEM ve Özel Etiket: Gaz ekipmanı distribütörleri ve sistem entegratörleri için özel boya renkleri, markalı isim levhaları ve yerelleştirilmiş dokümantasyon paketleri.

Özel yapılandırmalar şu adresten temin edilebilir: Minimum sipariş miktarı 1 adetMühendislik incelemesi ve teklif hazırlama genellikle 5-7 iş günü sürer. Standart teslim süresi 12-14 haftadır; tekrarlanan siparişler, sipariş onayından itibaren 8-10 hafta içinde teslim edilir.

Case Study: Chemical Synthesis Plant Nitrogen Injection Upgrade

Müşteri: A specialty chemical manufacturer in Indonesia operating high-pressure batch reactors for polymer production

Meydan okumak: The plant required ultra-high-pressure nitrogen (2.80–3.00 MPa) for reactor inerting and catalyst bed preservation during batch polymerization cycles. Their existing oil-lubricated compressor (imported European brand, 12 years in service) was experiencing severe oil carryover into the nitrogen stream, with contamination levels reaching 5.2 mg/m³. This oil contamination was poisoning the Ziegler-Natta polymerization catalyst, reducing catalyst efficiency by 30% and causing off-specification polymer batches. The oil was also fouling the reactor heat transfer surfaces, requiring quarterly chemical cleaning. Annual maintenance costs had escalated to $65,000.

Çözüm: Biz tedarik ettik 3ZW-6/30 oil-free nitrogen compressor as the primary high-pressure nitrogen source, configured on a custom skid with three integrated intercoolers, aftercooler, and a Siemens S7-1200 PLC control panel with stage-by-stage pressure monitoring. The 3.00 MPa discharge pressure met the reactor inerting requirements with a safety margin. The oil-free design eliminated catalyst poisoning and reactor fouling. A 2 m³ surge vessel was installed upstream to buffer demand fluctuations from the batch reactor cycle.

18 Ay Sonra Elde Edilen Nicel Sonuçlar:

• Azotlu yağ içeriği: Reduced from 5.2 mg/m³ to <0.01 mg/m³ISO 8573-1 Sınıf 0'ı elde etmek
• Catalyst efficiency: Restored to 95% (from 65%), reducing catalyst consumption by 32%
• Off-specification batches: Tamamen ortadan kaldırıldı, saving $45,000/year in rework costs
• Reactor cleaning frequency: Üç aylıktan yıllık hale düşürüldü., saving $18,000/year
• Yıllık bakım maliyeti: 48% kadar azaltıldı ($65,000 to $33,800)
• Geri ödeme süresi: 1.6 years based on catalyst savings, rework elimination, and maintenance reduction

“The 3ZW-6/30 has transformed our polymerization process. The elimination of oil contamination has restored our catalyst performance to design levels and eliminated our off-spec batch problem. Our maintenance team now spends their time on preventive activities rather than emergency oil-related repairs. The payback was faster than our finance team projected.” — Production Director, Specialty Chemical Plant

Sıkça Sorulan Sorular ve Seçim Kılavuzu

İlgili Ürünler ve Çözümler

Hizmetlerimizin kapsamlı bir özetini görmek için endüstriyel azot kompresörü Yağsız oksijen kompresörleri, hidrojen kompresörleri, karbondioksit kompresörleri ve özel olarak tasarlanmış özel gaz çözümleri de dahil olmak üzere ürün portföyümüz hakkında daha fazla bilgi için lütfen uygulama mühendisliği ekibimizle iletişime geçin veya çevrimiçi ürün kataloğumuza göz atın.

Ultra yüksek basınçlı nitrojen sisteminizi yükseltmeye hazır mısınız?

Uygulama mühendislerimiz, nitrojen akış gereksinimlerinizi, emme koşullarınızı, deşarj basıncı hedeflerinizi ve entegrasyon kısıtlamalarınızı değerlendirmek için hazır bekliyor. Talebinizi aldıktan sonraki 48 saat içinde ücretsiz teknik teklifler, temel yerleşim çizimleri, borulama ve enstrümantasyon diyagramları (P&ID'ler) ve ayrıntılı toplam sahip olma maliyeti (TCO) analizleri sunuyoruz.

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