Internal Structure Frontside
Internal Structure Backside
Working Principle
In an ideal air compression process, the power required for single-stage pressure transmission is technically equivalent to the cumulative power needed for multi-stage compression. However, in practical applications, the effective working power is higher due to factors like coupling transmission power loss, bearing friction coefficients, and the cooling effects of liquid viscosity, among others. By optimizing the compression ratio of each stage, the overall power required for multi-stage compression can be reduced, making it more efficient than single-stage compression.
The two-stage screw air compressor consists of a dual rotary screw system, with each stage having an active and a passive screw. The active screw propels the passive screw through an external power transmission mechanism. In the first stage, the compressor uses a low-pressure rate screw group, while the second stage employs a high-pressure rate screw group. Each screw is enveloped by a sealing air film. As they rotate, the gas undergoes compression via three processes: suction, pressurization, and exhaust.
First Stage Compression: The initial stage of the two-stage screw air compressor utilizes a low-pressure rate screw group. Gas is drawn into the screw compression chamber through the suction valve and then squeezed out under the high-speed rotation of the screw rotor, transferring it to the second stage.
Second Stage Compression: In this stage, the gas enters a more confined screw space, subjected to higher temperature and pressure. The exhaust valve opens to expel the high-pressure gases from the system, completing the compression cycle.
Natural air first enters the compression system through an air filter, mixing with a small amount of lubricating oil in the compression chamber. This mixed gas is compressed to interstage pressure and then cooled as it passes through an oil-mist-rich cooling channel. The cooled, compressed gas is further compressed in the second-stage rotor to the final exhaust pressure, after which it is expelled through the exhaust valve, culminating the entire compression process.
Water-cooled compressors utilize water as the primary cooling medium. As the cooling water circulates through the air compressor, it plays a dual role in cleaning and lubrication, thereby extending the lifespan of friction-wearing components. During operation, the cooling water effectively dissipates heat from the cylinder and the compressed gas, which significantly reduces exhaust temperatures and power consumption, ultimately lowering operational costs. However, it is crucial to monitor and address potential scaling issues within the water cooling system.
1) High efficiency of PM motor:The permanent magnet (PM) motor boasts a broader constant torque range and a weak magnetic range. Its efficiency surpasses that of a regular motor by 20-30%. Even when operating away from its rated frequency, the PM motor maintains consistently high efficiency.
2) Motor maintenance-free:The permanent magnet motor is designed without internal bearings, eliminating both the need for and the cost associated with bearing maintenance and replacement.
3) Integrated frequency converter:Utilizing China's top frequency system, this design offers a wide range of speed regulation and high precision. By adjusting the frequency modulation according to the user's actual gas demand, the air compressor achieves remarkable energy-saving results.
4) No transmission loss:The permanent magnet motor and compressor are directly connected via an embedded integrated shaft, resulting in a more compact structure and eliminating the need for couplings and other transmission parts. This design ensures 100% transmission efficiency.
5) Variable frequency start and soft start:The motor's variable frequency start and soft start capabilities significantly reduce the impact on power grid equipment, preventing damage to electrical systems.
6) Reduce energy consumption:With a frequency conversion range of 25% to 100% (compared to the 50% to 100% range of ordinary frequency converters), this system can save over 30% more energy than fixed-speed air compressors. Compared to standard variable frequency air compressors, energy savings are approximately 5%. The more significant the fluctuation in system gas consumption, the more noticeable the energy-saving effect.
7) Two-stage compression unique air end:This design features a unique air end for two-stage compression screw machines, combining both the first-stage and second-stage compression rotors within a single case. Each rotor achieves optimal linear speed through direct gear rotation, enhancing compression efficiency.
8) Internal spray curtain cooling method:Employing an internally-sprayed curtain cooling method, this system achieves excellent cooling effects, significantly reducing the temperature of compressed air. This method approaches isothermal compression, reduces pressure loss between stages, lowers the compression ratio, and improves overall compression efficiency.
9) Reduce internal leakage:The adoption of two-stage compression minimizes the compression ratio for each stage, thereby reducing internal leakage from the high-pressure to the low-pressure end and enhancing volumetric efficiency.
10) Noise reduction:Two-stage compression decreases the overall compression ratio, substantially reducing noise levels, particularly the noise generated during unloading.
11) Easy maintenance and service:The two-stage compressor unit retains similar systems and structures to single-stage compression, aside from the screw air end. This design simplifies maintenance and servicing for users.
1. Competitive Pricing
We offer customers ex-factory prices directly, ensuring that our partners remain highly competitive in the marketplace.
2. Direct Dealings
All products are supplied straight from the factory, guaranteeing you access to more cost-effective and high-quality options.
3. Comprehensive OEM & ODM Services
Our factory's robust production and management capabilities allow us to provide exceptional OEM and ODM services tailored to your needs.
4. Personalized Customization
We welcome non-standard, export, and specific orders for voltage, power, pressure, and more. For any special requirements, please reach out to us.
5. Flexible Small Orders
Initiate a small trial order to assess the superior quality of our products.
6. Rapid Delivery
Experience timely delivery of premium products, ensuring your operations run smoothly.
7. Complete Authorization
For our valued distributors, we provide full authorization certificates, empowering you to market SANZHI brand products effectively.
Sanzhi (Henan) Compressor Co., Ltd., boasts over a decade of expertise in manufacturing state-of-the-art screw air compressors and screw vacuum pumps. Our extensive and versatile product line includes normal pressure/low-pressure screw air compressors, permanent magnet frequency conversion screw air compressors, two-stage compression screw air compressors, screw air compressors for laser cutting, single-tank mobile screw air compressors, double-tank mobile screw air compressors, electric mobile screw air compressors, diesel mobile screw air compressors, screw vacuum pumps, and more.
Our production capabilities are maximized through advanced, lean multi-air compressor assembly lines, ensuring the highest efficiency. Supported by a dedicated team of over 50 employees, we continuously refine our management systems, such as ERP, to minimize lead times and deliver top-quality products swiftly.
Our commitment to quality is unwavering, as evidenced by our ISO9001 quality management system certification. We strictly adhere to rigorous quality management protocols, including meticulous material inspections, thorough production checks, and comprehensive pre-delivery examinations, ensuring each machine meets our stringent standards.
Our customer service is unparalleled. Pre-sales, we provide expert guidance in selecting air equipment tailored to various facilities, offering extensive customization options in appearance and configuration, including OEM solutions. Post-sales, our highly trained sales and service team is ready to provide swift and efficient responses to any customer inquiries or needs.
At Sanzhi (Henan) Compressor Co., Ltd., we are dedicated to delivering superior, stable products. We aim to build enduring relationships with our customers through our reliable, efficient deliveries, high-quality machines, and competitive pricing. Trust us to provide you with an exceptional compressed air solution.
Our factory is conveniently located in Xinzheng City, Henan Province, China. We offer complimentary transportation from Xinzheng International Airport to our factory, a brief 30-kilometer journey taking about one hour. We warmly invite you to visit our company!
FAQ
Q1. Are you a trading company or manufacturer?
A: We are a seasoned manufacturer of screw air compressors, with over a decade of experience in the industry.
Q2. How do you control quality?
A: 1. Rigorous inspection of raw materials.
2. Stringent control of installation procedures.
3. Each machine undergoes a minimum of 5 hours of continuous testing before dispatch to ensure optimal performance.
Q3. What information must I provide to get the suitable machine?
1. Required air delivery capacity (Unit: CFM or m³/Min)
2. Desired working pressure (Unit: PSI, Bar, or Mpa)
3. Voltage and frequency specifications of your country (V/Hz)
4. Any additional accessories needed, such as air tanks, filters, or air dryers.
Provide this information, and we will engineer the perfect solution tailored for you!
Q4. What is the general unit conversion?
1 Bar = 0.1 Mpa = 14.5 PSI
1 m³/min = 35.32 cfm
1 KW = 1.34 HP
Q5. What is the available voltage air compressor?
A: Sanzhi offers a comprehensive range of voltage options including 380v/50hz/3p, 400v/50hz/3p, 415v/50hz/3p, 220v/60hz/3p, and 440v/60hz/3p, with customization available to meet your specific requirements.
Q6. How long is the delivery time?
A: For our standard voltage models, enjoy the benefit of expedited delivery within just 15 working days from order confirmation. For non-standard models, please feel free to contact our dedicated and knowledgeable sales team for personalized assistance.
Q7. What's the payment term?
A: Secure your order with a 30% T/T deposit, followed by a 40% T/T payment before shipment. The remaining 30% T/T is due upon presentation of the B/L copy. We are pleased to accept payments in both USD and RMB for your utmost convenience.
Q8. How about your warranty?
A: Enjoy unmatched peace of mind with our comprehensive warranty: one year for the entire machine and an extended two-year warranty specifically for the screw air compressor, excluding consumable spare parts.
Q9. What about the maintenance?
A: The first maintenance is required after 500 hours of operation, with regular maintenance every 2000-3000 hours thereafter. Always consider the actual working environment to optimize performance.
Q10. Can machines be run in high-temperature environments?
A: Absolutely, our machines are meticulously engineered to perform efficiently in high-temperature environments, with a robust working temperature range from -20° to 45° (-4ºF to 113ºF).
Q11. Do you offer OEM service?
A: Yes, we are proud to offer both OEM and ODM services, supported by our professional design team. Bring your innovative ideas to life with our expertise.
Q12. How long could your air compressor be used?
A: Typically, our air compressors boast an impressive lifespan exceeding 10 years, ensuring long-term reliability and performance.
Q13. Will you provide some spare parts for the machines?
A: Certainly, we provide essential spare parts to ensure the seamless and uninterrupted operation of your machines.
Q14. How about your after-sales service?
A: We offer comprehensive after-sales support, including detailed online installation and commissioning instructions. Additionally, our engineers are available for on-site training and installation assistance to ensure optimal performance.
){kind=link}