ZW-0.97/7.5~30 Nitrogen Compressor – Compact Variable Inlet Oil-Free N2 Booster for Medium-Pressure Recycle

Engineered to deliver 0.97 m³/min at 3.00 MPa discharge pressure with 0.75 MPa inlet capability, the ZW-0.97/7.5~30 is a two-stage, single-row oil-free piston nitrogen compressor designed for small-scale nitrogen recycle, gas liquefaction booster circuits, and medium-pressure process applications with variable inlet conditions. Zero oil contamination, ultra-compact footprint, and optimized for continuous-duty operation.

产品概述

这 ZW-0.97/7.5~30 nitrogen compressor is a compact yet capable solution within our oil-free piston compressor family, distinguished by its variable inlet pressure capability spanning from 0.75 MPa up to the discharge pressure of 3.00 MPa. With a rated capacity of 0.97 m³/min and a discharge pressure of 3.00 MPa, this unit occupies the entry-level segment of our high-pressure nitrogen compressor portfolio while maintaining the same engineering rigor as our larger models.

What makes the ZW-0.97/7.5~30 unique is its ability to accept inlet nitrogen at pressures up to 0.75 MPa, as indicated by the model designation “7.5~30” (representing inlet pressure range of 0.75 MPa to 3.0 MPa). This variable inlet capability eliminates the need for upstream pressure reduction when feeding from medium-pressure nitrogen headers or process vents, improving overall system efficiency and reducing pressure losses. The compressor can also operate from atmospheric or low-pressure inlet when required, providing exceptional operational flexibility for small-scale installations.

The compressor employs a two-stage, single-row (二列一级) configuration that is optimized for the moderate pressure ratio required when boosting from 0.75 MPa to 3.00 MPa. The single-row design minimizes mechanical complexity and footprint 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 at elevated pressure.

Technical Specifications – ZW-0.97/7.5~30

* 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 0.75 MPa inlet pressure; actual capacity varies with inlet pressure.

主要特性及工程优势

1. Variable Inlet Pressure Capability (0.75–3.00 MPa)

The ZW-0.97/7.5~30 is uniquely engineered to accept inlet nitrogen across a broad pressure range from 0.75 MPa up to 3.00 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 0.75 MPa, the compressor operates at its rated 0.97 m³/min capacity. As inlet pressure increases toward the discharge pressure, the compressor transitions into a pressure-maintaining or recycle mode with progressively 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-0.97/7.5~30 ideal for nitrogen recycle loops and process systems with variable upstream pressure.

2. Ultra-Compact Footprint for Space-Constrained Installations

At 2035 × 1240 × 2234 mm, the ZW-0.97/7.5~30 occupies less than 2.5 m² of floor space, making it one of the most compact high-pressure oil-free nitrogen compressors available. This dimensional efficiency is achieved through a vertically oriented crankcase design and a single-row cylinder arrangement that minimizes the machine’s longitudinal footprint. At just 2.60 tonnes, the unit can be transported and positioned using standard forklift equipment, eliminating the need for overhead cranes or specialized rigging. This compact form factor is particularly valuable for retrofit installations in existing process plants, containerized systems, and mobile nitrogen supply units where floor space is at a premium.

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

The ZW-0.97/7.5~30 utilizes a proprietary 自润滑活塞环和导向带组件 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 3.00 MPa discharge pressure, the partial pressure of any oil vapor would be significantly magnified, making oil-free design absolutely essential for applications requiring high-purity nitrogen. The PTFE formulation is specifically rated for continuous operation at temperatures up to 180°C, ensuring reliable sealing integrity under the thermal stress of high-pressure compression.

4. Standard 380V Drive with Low Power Consumption

The ZW-0.97/7.5~30 is driven by a 45 kW, 380V, 50Hz three-phase induction motor conforming to IEC 60034-1 efficiency class IE3. The modest power requirement of 45 kW makes this unit accessible to virtually any industrial facility with standard 380V distribution, without requiring electrical infrastructure upgrades or medium-voltage switchgear. The low power consumption also translates to lower operating costs and reduced cooling requirements, making the ZW-0.97/7.5~30 an economically attractive option for small to medium nitrogen systems.

应用场景

Small-Scale Nitrogen Recycle & Recovery

In small chemical process plants and gas treatment facilities, the ZW-0.97/7.5~30 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 systems, delivering substantial operating cost savings for small-scale operations where every efficiency gain matters.

Gas Liquefaction & Cryogenic Booster Duty

In small-scale nitrogen liquefaction plants and cryogenic systems, the ZW-0.97/7.5~30 nitrogen booster compresses nitrogen from the liquefier vaporizer or storage tank 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, or supplying high-pressure process equipment. The variable inlet capability allows the compressor to accept nitrogen directly from the liquefier at its operating pressure, eliminating intermediate pressure reduction and improving overall plant efficiency.

Pilot Plant & R&D High-Pressure Nitrogen Supply

Research laboratories and pilot-scale chemical plants require high-pressure nitrogen for high-pressure reactor inerting, catalyst testing under pressure, and supercritical fluid experiments. The ZW-0.97/7.5~30’s compact footprint and standard 380V electrical supply make it ideal for installation in laboratory utility rooms or pilot plant buildings. The 3.00 MPa discharge pressure is adequate for most pilot-scale high-pressure applications, while the oil-free certification ensures that nitrogen purity meets the stringent requirements of research-grade experiments and analytical instrumentation. The variable inlet capability is particularly valuable in R&D environments where experimental conditions change frequently.

Medium-Pressure Header Pressure Maintenance

Industrial facilities with medium-pressure nitrogen distribution headers (0.75–1.50 MPa) often require a pressure maintenance compressor to compensate for demand fluctuations and pipeline losses. The ZW-0.97/7.5~30 can accept nitrogen directly from the header at its operating pressure and boost it to 3.00 MPa for high-pressure consumers or back into the header to maintain pressure during peak demand periods. This dual-mode operation provides exceptional operational flexibility and reduces the need for separate compressor units, making it an economically efficient solution for small to medium facilities.

材料与施工

The ZW-0.97/7.5~30 is constructed from materials selected for high-pressure nitrogen compatibility, thermal resistance, and compact structural integrity:

All pressure-bearing components are designed and fabricated in accordance with ASME BPVC 第 VIII 节第 1 部分 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 3.00 MPa operating pressure.

安装和维护指南

Foundation & Spatial Requirements

The ZW-0.97/7.5~30 has a dry weight of 2.60 tonnes and a center of gravity approximately 700 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 3.00 MPa.

Cooling Water Specifications

冷却水需求量约为 8 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.

预防性维护计划

The oil-free design of the ZW-0.97/7.5~30 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 聚四氟乙烯活塞环和活塞环带, 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.

合规与安全认证

The ZW-0.97/7.5~30 nitrogen compressor is designed, manufactured, and tested to meet or exceed the following international standards and regulatory frameworks:

性能与效率分析

The ZW-0.97/7.5~30 achieves a specific power consumption of approximately 46.39 kW per m³/min of nitrogen at 3.00 MPa discharge pressure from 0.75 MPa inlet. While this specific power appears high in absolute terms, the true efficiency advantage lies in the ability to accept high-pressure inlet without energy-wasting pressure reduction. When compared to systems that throttle 0.75 MPa nitrogen down to atmospheric pressure before re-compressing to 3.00 MPa, the ZW-0.97/7.5~30 saves approximately 45–55% 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-0.97/7.5~30’s variable inlet capability yields approximately 80,000–120,000 kWh of energy savings compared to systems requiring upstream pressure reduction. At $0.08/kWh, this represents $6,400–$9,600 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-0.97/7.5~30’s native oil-free design ensures that nitrogen purity is maintained indefinitely in recycle service.

定制化和OEM能力

We offer flexible customization options to adapt the ZW-0.97/7.5~30 to specific site conditions and integration requirements:

• Skid-Mounted Packages: 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.
• Mobile Trailer Units: The ZW-0.97/7.5~30 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.
• PLC & Remote Monitoring: Optional Siemens LOGO! or S7-1200 PLC with HMI touchscreen, Ethernet connectivity, and SMS/email alarms. Compatible with Modbus TCP/IP for SCADA integration.
• Acoustic Enclosures: 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 such as laboratories and office-adjacent machinery rooms.
• OEM & Private Label: Custom paint schemes, branded nameplates, and localized documentation for gas equipment distributors and system integrators.

可提供自定义配置 最小起订量 1 件. Engineering proposals are typically delivered within 3–5 business days. Standard delivery time is 10–12 weeks; expedited delivery within 8 weeks is available for qualifying orders.

Case Study: Pilot Plant Nitrogen Recycle Optimization

客户： A specialty chemical R&D facility in Singapore operating multiple pilot-scale high-pressure reactors

挑战： The facility was purchasing high-pressure nitrogen cylinders for reactor inerting and purge operations, consuming approximately 200 cylinders per month at a cost of $15,000/month. The spent nitrogen was vented to atmosphere at 0.60–0.90 MPa after passing through the reactors, representing a significant waste of both gas and energy. The facility wanted to recover and recycle this nitrogen but needed a compact compressor capable of accepting variable inlet pressure and boosting it to 2.50 MPa for re-use in the high-pressure reactor feed system.

解决方案： 我们提供了 ZW-0.97/7.5~30 oil-free nitrogen compressor configured on a compact 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 (0.60–0.90 MPa), eliminating the need for upstream pressure regulation. A 0.5 m³ surge vessel was installed upstream to dampen pressure fluctuations from the batch reactor cycle.

Quantified Results After 18 Months:

• Nitrogen cylinder purchases: Reduced by 72% (from 200 to 56 cylinders/month), saving $10,800/month
• Nitrogen vent emissions: Reduced by 72%, improving environmental compliance
• Oil contamination in recycled nitrogen: <0.01 mg/m³, ensuring no reactor contamination
• Compressor availability: 97.8% over 18 months, with only scheduled maintenance downtime
• Payback period: 1.4 years based on cylinder cost savings alone

“The ZW-0.97/7.5~30 has transformed our nitrogen supply from a recurring expense into a closed-loop system. We’ve cut our cylinder purchases by nearly three-quarters, and the compact size meant we could install it in our existing utility room without any building modifications. The variable inlet feature was the key that made this project work.” — R&D Operations Manager, Specialty Chemical Facility

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Ready to Optimize Your Small-Scale Nitrogen Recycle System?

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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