Screw Air Compressor – Enhancing Operational Efficiency and Reliability

Screw air compressors are the backbone of many manufacturing operations, used to power pneumatic tools like sandblasters, sprayers and jack-hammers.

An oil-flooded rotary screw compressor uses lubricating oil as a hydraulic seal and energy transfer medium between its male and female rotors to provide a hydraulic seal and transfer mechanical energy efficiently. Once air and oil mixture exits the system, it travels to a separator where it is cooled, filtered, and routed back into air end for relubrication purposes.

Durability

Screw air compressors use two interlocking rotors within an air end unit that rotate and reduce volume before being transferred to an air-receiver tank for use.

Oil-injected models achieve higher PSIG and run cooler; however, any residual oil present poses a contamination risk and are therefore less suited for certain industrial processes.

Genuine rotary air compressor manufacturers typically create these parts themselves within their facilities using in-house foundries and computer numerical control machines to meet exact tolerances, eliminating third-party expenses for machining while keeping full control over the design process.

Reliability

Screw-type compressors are reliable workhorses in air compressor technology, easily meeting the rigorous demands of industrial processes and applications. Used for everything from heavy construction equipment like pneumatic hammers to agricultural sprayers and tractors, screw-type compressors have proven themselves as essential workhorses in their field.

Screw-type compressors compress air through an air end (also referred to as the suction or discharge valve) housed within a housing unit containing rotors, drawing air in through its suction/discharge valve and forcing its passage through a housing with the rotors meshing synchronously to reduce their volume and create compression.

Oil is added to the system in order to reduce friction and heat within the chamber, and enable free rotor movement. Lubrication, cooling, wear protection and trapping contaminants are among other functions performed by this oil within rotary screw air compressors.

Energy Efficiency

Rotary screw air compressors can be some of the most energy-efficient compressors available when properly sized; however, to optimize energy efficiency they also need an effective air system design and intelligent compressor control system.

Atmospheric air enters the system through the suction side of an air compressor (known as “air end”). Here, two interlocking rotors compress this volume of atmospheric air by compressing its flow.

Lubricating oil bridges the gap between the rotor vanes to lubricate and seal the compressor, while providing mechanical seal functionality. Once out of the compressor it enters an oil-return line where it can be cooled, filtered, and recycled back into the air end – creating an energy-saving closed loop oil system which reduces energy usage by eliminating an external oil cooler while simultaneously decreasing waste generation.

Space-Saving Design

Screw air compressors are small enough to fit into tight spaces easily, making them the ideal solution for tight installations. Furthermore, their energy consumption is less than other types of air compressors, leading to reduced wasteful energy use and carbon emissions – an essential characteristic for businesses committed to sustainability.

Compressed air systems allow businesses to pressurize and store compressed air without interruption, as well as require minimal maintenance to reduce downtime and costs.

Maintaining proper lubrication is integral to optimizing efficiency. Engaging in regular oil analysis programs helps detect any issues before they lead to performance loss or equipment damage, helping reduce energy consumption and enhance system reliability while preventing wear-and-tear damage on other components of the facility.

Maintenance

Screw air compressors are relatively straightforward to maintain due to having minimal moving or contacting parts, and have long service intervals, thus lowering maintenance expenses significantly – making them an economical option for industrial plants.

Air pressure is stable and suitable for supporting various tasks, from powering pneumatic tools and equipment, to providing precise testing results, while its low noise level creates a relaxing workplace.

Maintaining peak performance requires regular maintenance checks for an air compressor. Inspect and clean all filters regularly while also inspecting and maintaining its air inlet to prevent dirt clogging the filter, then ensure temperature stays within manufacturer recommendations range.