ZHL Single-Stage Air Compressor

Basic technical specifications
FAD capacity in l/s
1 944 l/s - 10 833 l/s

FAD capacity
7 000 m³/h - 39 000 m³/h

Working pressure
0.8 bar(e) - 2 bar(e)

Installed motor power
355 kW - 1 400 kW

FAD capacity in m³/min
115 m³/min - 650 m³/min

What is a single-stage centrifugal air compressor?
Centrifugal air compressors use centrifugal forces to generate flow and pressure. Centrifugal technology is a highly efficient way to produce compressed air. The gearbox, which contains the main drive shaft, is driven by a motor. Both the gearbox and the main drive shafts drive high-speed shafts with one or more turbines. Single-stage turbochargers have only one turbine and deliver air at pressures up to 2 bar(g).

What is the difference between single-stage and two-stage compressors?
The word "stage" refers to the number of compression stages the air passes through to reach the required air pressure. The high-speed rotating turbines create a dynamic pressure buildup in the compressor. The number of turbines and the resulting number of stages depend on the required output pressure. If applications require pressures of 2 bar(g) or less, a single-turbine or single-stage compressor is sufficient to meet the pressure demand. Higher pressures can be achieved with a two-stage (or three-stage) compressor.

Benefits
What makes our single-stage turbo oil-free air compressors unique?
With the ZHL design, we offer a more energy-efficient solution for applications requiring flow rates of 7000 m3/h or more and pressures up to 2 bar(g)/29 psig. This innovative design ensures efficient air distribution, even when process air demand fluctuates.

In addition, our units are Class 0 certified, ensuring oil-free, high-quality air for your process. The unique double-seal design ensures a high-quality air production process. Thanks to the oil and air seals, no lubricating oil can enter the turbines, resulting in oil-free, Class 0-certified air.

Sustainable production process
Up to 80% of total lifecycle costs are spent on energy consumption. Therefore, designing compressors as energy-efficient as possible is both beneficial to the planet and provides a return on investment for you. Ensuring the highest energy efficiency of your compressed air installation is a great way to make your production process more sustainable.

Sustainability is at the core of our design process:

• Our turbocompressor utilizes every power and pressure model with our exclusive backward-sloping turbine design. Different turbine types allow for the correct geared turbocompressor sizing for a wide variety of applications. Regardless of operating points, our wide range of turbine types allows you to optimize performance to your specific requirements.
• Our ZHL turbocompressors are powered by a wide variety of high-efficiency motors. Low-voltage models (up to 560 kW) come with internal star-delta starters. A variety of motor options are available, both air- and water-cooled.
• Inlet guide vanes are an effective way to adjust the flow rate when air demand is variable. Adjustable inlet guide vanes provide energy savings of up to 9% compared to using inlet valves. The inlet guide vanes are controlled by a servomotor-based actuator. This is a cost-effective and reliable way to control flow rate for varying air demands across the compressor's full reduction range.
• Our aftercoolers combine compact design with low approach temperature and minimal pressure drop to maximize overall energy efficiency.

Towards a Carbon-Free Production Process

Our single-stage turbo compressor, combined with an energy-efficient core design, an energy recovery unit, and a central and/or unit control unit, further reduces the carbon footprint of your production process:

• An operating compressor inevitably generates heat. Adding an Energy Recovery unit can help you recover up to 94% of the heat of compression. Without energy recovery, this heat is lost to the atmosphere through the cooling system and radiation. Our Energy Recovery unit uses the heat of compression to heat water. This hot water can be used for sanitary purposes, space heating, or reused elsewhere in your process.
• Our Elektronikon® control unit's standard step-down optimization algorithm continuously maximizes the unit's step-down range. This limits unloading and increases energy efficiency under all operating conditions.
• ZHL compressors can be easily paired with the Optimizer 4.0 central control unit. The central control unit allows for accurate division of work across multiple compressors, resulting in less wear, more control options, and lower energy consumption.