Internal Structure Frontside
Internal Structure Backside
Working Principle
In an ideal air compression process, the power required for single-stage pressure transmission equals the sum needed for multi-stage compression. However, in reality, the actual working power is higher due to transmission power loss, bearing friction, and liquid viscosity cooling effects. Thus, minimizing the compression ratio at each stage efficiently reduces useless power. This ensures that the total energy required for multi-stage compression is indeed less than that for single-stage compression.
The two-stage screw air compressor consists of a rotary screw compressor with two stages. Each stage contains an active and a passive screw, where the active screw drives the passive screw via an external power transmission device. The first stage employs a low-pressure rate screw group, while the second stage uses a high-pressure rate screw group. Each screw is surrounded by a sealing air film. During rotation, the gas undergoes three processes: suction, pressurization, and exhaust.
First Stage Compression: In the initial stage of the two-stage screw air compressor, a low-pressure rate screw group compresses the gas. The gas enters the screw compression chamber through the suction valve, and the high-speed rotation of the screw rotor gradually forces the gas out, transferring it to the second stage.
Second Stage Compression: Here, the gas enters a denser screw space, facing higher temperatures and pressures. The exhaust valve then opens to expel the high-pressure gases from the system.
The natural air first passes through an air filter and enters the initial compression stage, mixing with a small amount of lubricating oil in the compression chamber. This mix is compressed to the interstage pressure. The compressed gas then moves through the cooling channel, encountering a significant amount of oil mist which substantially lowers its temperature. Subsequently, the cooled, compressed gas enters the second-stage rotor, undergoes further compression to the final exhaust pressure, and is finally discharged through the exhaust valve, completing the entire compression process.
Our state-of-the-art water-cooled compressors utilize water as the primary cooling medium. This innovative approach ensures that as the cooling water circulates within the compressor, it effectively cleans and lubricates the system, significantly extending the life of friction-wearing components. Moreover, during operation, the cooling water dissipates heat from both the cylinder and the compressed gas, substantially reducing exhaust temperature and power consumption, which in turn lowers the overall operating costs. It is important to manage the scaling issues within the water cooling system to maintain optimal performance.
1) Superior Efficiency of PM Motor:Our permanent magnet (PM) motor boasts a broader constant torque range and a wider weak magnetic range. This results in an efficiency increase of 20-30% compared to regular motors. Remarkably, the PM motor maintains its high efficiency even when operating away from its rated frequency, ensuring consistently exceptional performance.
2) Maintenance-Free Motor:The innovative design of the permanent magnet motor eliminates the need for internal bearings, thereby eradicating the costs associated with motor bearing maintenance and replacement.
3) Integrated Frequency Converter: Equipped with China's top-tier frequency system, this feature offers extensive speed regulation and high precision. By modulating operation based on the user's actual gas demand, this system delivers remarkable energy-saving benefits for the air compressor.
4) Zero Transmission Loss: The design integrates the permanent magnet motor and compressor through a direct-connected, embedded integrated shaft structure. This compact configuration eliminates coupling and other transmission parts, ensuring 100% transmission efficiency.
5) Variable Frequency Start and Soft Start Functionality:This feature greatly diminishes the impact on power grid equipment and prevents any potential damage to the electrical components.
6) Energy Consumption Reduction: Our frequency conversion range extends from 25% to 100% (compared to the typical 50% to 100% range), yielding energy savings of over 30% when compared to fixed-speed air compressors. Additionally, it offers approximately 5% more energy savings than ordinary variable frequency air compressors, with more significant savings in systems with higher gas consumption fluctuations.
7) Unique Two-Stage Compression Air End:Featuring a distinctive design, the two-stage compression screw machine integrates the first-stage and second-stage compression rotors within a single casing. These rotors are independently rotated through gears, optimizing linear speed and enhancing compression efficiency.
8) Advanced Internal Spray Curtain Cooling Method: Utilizing a highly energy-efficient internal spray curtain cooling method, this innovative approach greatly reduces the temperature of compressed air, achieving near-isothermal compression. This method also minimizes pressure loss between the first and second stages, lowers the compression ratio, and enhances overall compression efficiency.
9) Minimized Internal Leakage:Adopting a two-stage compression system reduces the compression ratio for each stage, decreasing internal leakage from the high-pressure to the low-pressure end, and thereby improving volumetric efficiency.
10) Noise Reduction:The implementation of two-stage compression significantly lowers the compression ratio, resulting in a substantial reduction in noise levels, particularly during unloading.
11) Simplified Maintenance and Service:Despite its advanced two-stage compression capability, the overall structure and systems of the unit remain similar to those of single-stage compressors, ensuring ease of maintenance and user convenience.
1. Exceptional Price Advantage
We offer our customers direct ex-factory prices, ensuring you gain a competitive edge in the market.
2. Direct Deal Assurance
All our products are dispatched directly from the factory, guaranteeing more cost-effective solutions for you.
3. Comprehensive OEM & ODM Services
Thanks to our factory's robust production and management capabilities, we can seamlessly provide OEM/ODM services tailored to your needs.
4. Bespoke Customization Services
We accommodate non-standard, export, and custom orders related to voltage, power, pressure, and more. Reach out if you have specific requirements.
5. Flexible Small Order Acceptance
Start with a small trial order to evaluate the superior quality of our products before committing to larger quantities.
6. Swift and Reliable Delivery
Experience the excellence of our high-quality products coupled with prompt and reliable delivery services.
7. Full Authorization for Distributors
We provide comprehensive authorization certificates for distributors, empowering you to sell our prestigious SANZHI brand products with confidence.
Sanzhi (Henan) Compressor Co., Ltd is a distinguished manufacturer specializing in the production of cutting-edge screw air compressors and vacuum pumps, boasting over a decade of industry expertise. Our extensive product lineup encompasses normal pressure and low-pressure screw air compressors, permanent magnet frequency conversion screw air compressors, advanced two-stage compression screw air compressors, specialized air compressors for laser cutting, single-tank and double-tank mobile screw air compressors, highly efficient electric and diesel mobile screw air compressors, and robust screw vacuum pumps, among others.
Our production process is streamlined for maximum efficiency, utilizing state-of-the-art multi-air compressor assembly lines that are both lean and modern. With a dedicated team of over 50 employees, we continuously enhance our management systems, including ERP, to drastically reduce lead times and ensure rapid delivery of high-quality products.
Our management practices are second to none, as evidenced by our ISO9001 quality management system certification. We are committed to the rigorous implementation of stringent quality management protocols, ensuring that each machine undergoes meticulous material inspection, production inspection, and pre-delivery inspection before it reaches our customers.
In terms of customer service, we excel in both pre-sales and after-sales support. Our pre-sales team provides expert guidance in selecting the ideal air equipment for various applications, with options for extensive customization, including appearance and configuration. We also offer OEM services to create unique products tailored to our dealers' specific needs. Our after-sales team is highly skilled and responsive, ensuring quick and effective support for all customer inquiries and issues.
At Sanzhi (Henan) Compressor Co., Ltd, we are dedicated to delivering superior, stable products and building long-term relationships with our valued customers. With our efficient delivery times, high-quality machines, and competitive pricing, we are your reliable partner for all your compressed air solution needs.
Our factory is conveniently located in Xinzheng City, Henan Province, China. We offer complimentary pick-up services from Xinzheng International Airport to our factory, which is just 30 kilometers away and about an hour's drive. We warmly welcome you to visit our company!
FAQ
Q1. Are you a trading company or manufacturer?
A: We are a dedicated manufacturer specializing in screw air compressors with over a decade of professional experience.
Q2. How do you control quality?
A: 1. Strict raw material inspection.
2. Rigorous control of installation procedures.
3. Each machine undergoes a minimum of 5 hours of continuous testing before dispatch.
Q3. What information must I provide to get the suitable machine?
1. The required air delivery capacity (Unit: CFM or m³/Min).
2. The necessary working pressure (Unit: PSI, Bar, or Mpa).
3. The voltage and frequency of your location (V/Hz).
4. Any additional accessories needed, such as an air tank, filters, or air dryers.
Provide us with these details, and we will tailor a solution for you!
Q4. What is the general unit conversion?
1Bar = 0.1Mpa = 14.5PSI
1m³/min = 35.32cfm
1KW = 1.34HP
Q5. What is the available voltage air compressor?
A: Sanzhi offers compressors in voltages of 380V/50Hz/3P, 400V/50Hz/3P, 415V/50Hz/3P, 220V/60Hz/3P, 440V/60Hz/3P, and can customize according to your requirements.
Q6. How long is the delivery time?
A: For standard voltage specifications, our lead time is typically 15 working days following order confirmation. If custom non-standard voltage specifications are necessary, please reach out to our sales team for precise delivery timelines.
Q7. What's the payment term?
A: Our payment terms are carefully structured to ensure smooth transactions: an initial 30% T/T deposit in advance, followed by 40% T/T before shipment, and the remaining 30% T/T upon receipt of the B/L copy. We accept payments in both USD and RMB.
Q8. How about your warranty?
A: We offer an extensive warranty program: one year for the entire machine and an impressive two years for the screw air compressor, with the exclusion of consumable spare parts.
Q9. What about the maintenance?
A: The initial maintenance should be performed after 500 operating hours. Subsequent maintenance intervals are recommended between 2000-3000 hours, depending on specific working conditions.
Q10. Can machines be run in high-temperature environments?
A: Absolutely, our machines are meticulously engineered to perform efficiently in high-temperature environments, operating flawlessly within a temperature range from -20° to 45° (-4ºF to 113ºF).
Q11. Do you offer OEM service?
A: Yes, we provide both OEM and ODM services. Our expert design team ensures maximum flexibility to meet your specific requirements.
Q12. How long could your air compressor be used?
A: Our air compressors are masterfully built for durability, boasting a typical lifespan that exceeds 10 years.
Q13. Will you provide some spare parts for the machines?
A: Yes, we guarantee the availability of essential spare parts for all our machines.
Q14. How about your after-sales service?
A: We offer robust after-sales support, including online guidance for installation and commissioning. Additionally, we can dispatch skilled engineers for on-site training and installation assistance.
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