Rotary Screw Compressors – The Workhorses of Industry and Manufacturing

The workhorses of industry and manufacturing, rotary screw air compressors are ideal for environments that need large volumes of high pressure compressed air. Learn more about these robust industrial air compressor systems in our complete guide.

In oil-injected rotary screw air compressors, lubricating oil bridges the gap between the meshed rotors to compress air and reduce its volume. This oil gets separated from the compressed air in a separator and is recycled back into the air end.

Energy efficiency

The simple design of a screw compressor allows for impressive energy efficiency. It only needs to compress air once, which reduces power consumption, resulting in lower operating costs than other types of compressors.

Unlike piston compressors, which produce compressed air in pulses, the rotary screw design offers continuous operation and fluid control of output. This makes it an ideal option for heavy-duty applications that require a steady stream of air over long periods of time, such as in manufacturing facilities or large automotive shops.

In oil injected rotary screw compressors (also known as oil-flooded compressors), lubricating oil bridges the space between rotor vanes, providing both a hydraulic seal and transferring mechanical energy between the driving and driven rotors. This system is then forced to compress air by the inter-twined rotors, and both the air and oil are separated before the air exits at the “air end” and is routed to air lines and a receiver. The oil is then cooled, filtered and re-routed back to the air end in a closed loop system. This method reduces energy loss and maintenance cost.

Less vibration

Screw compressors produce less vibration compared to other types of air compressors. This is because the helical screws that turn inside the compressor to compress the air don’t touch each other. They are also operated at a lower temperature and integrated with a good cooling system.

However, a screw compressor does not do well with intermittent compressed air demands that require it to cycle on and off. In such cases, it is recommended that you install a variable-speed drive motor to ramp air production up and down according to your requirements.

Additionally, when installing a screw compressor, extra cautions must be taken to ensure that the structure of a building doesn’t resonate with the primary frequency generated by the package (lobe passing frequency). This is particularly important when you’re dealing with higher discharge pressures on dense gases. If this is the case, a larger foundation should be used to support the package. This will prevent any unwanted noise screw compressor and vibration from being transmitted to the facility. This can be very disruptive to the work environment and needs to be avoided.

Less noise

Screw compressors are much quieter than reciprocating (also called piston) air compressors. They also consume less energy, which significantly reduces energy costs in your compressed air system. This can add up to thousands of dollars in savings every year.

A rotary screw air compressor can run at high temperatures, which helps prevent the formation of moisture in your equipment and the subsequent loss of production. They can also function in extreme weather without icing up, making them well suited to drilling rigs and other outdoor applications where the climate is unfavorable.

Because they use a rotating shaft, a screw compressor produces less mechanical noise, and BOGE’s patented whisper quiet technology further reduces it even more. This makes them ideal for use in industrial environments where noise levels are an issue. They are also suitable for continuous operation, but are not a good choice for intermittent loads because they require frequent cycling on and off. This can cause wear and tear to the machine. To avoid this, you should consider a variable speed air compressor that will ramp up and down depending on your needs.

Easy maintenance

With few moving and contacting parts, rotary screw compressors require little maintenance. This makes them ideal for applications that need continual operation as they reduce downtime caused by frequent starts and stops. This increases their lifespan and keeps energy costs low.

Oil-lubricated rotary air compressors are an efficient option for many applications. They’re also easy to maintain and work well in environments with high or low temperatures. Their design minimizes fluctuations in pressure, making them more efficient than other models.

If your compressor has trouble building up to pressure, you may need to replace the air filter, hose or inlet valve. You could also have an issue with the pressure switch or a faulty solenoid. In addition, you might have acidic or contaminated oil that requires changing. To prevent these issues, keep a regular schedule of air compressor screw compressor manufacturer maintenance and inspections. This will help you identify mechanical issues before they become costly problems. It will also make sure that your employees are working with clean, fresh and safe compressed air. It will also minimize heat, noise and vibration in the workplace.

Adaptability

A screw compressor traps air between two meshed rotors and reduces its volume as it moves down the rotors to create compressed air. This type of air is used for a variety of applications, from powering air tools to inflating tires and more. Because of their continuous operation and ability to produce a high volume of air at a low pressure, rotary screw compressors are ideal for applications that require large amounts of high quality air in a consistent fashion.

They are not recommended for intermittent use, as turning them on and off often causes water to condensate in the system and can lead to problems with the compressor bearings and high oil carry-over. Instead, we recommend a variable-speed drive motor that will help the compressor ramp up and down to match actual demand.

Because they are designed for 100% duty cycle, rotary air compressors have extremely precise tolerances that manufacturers are required to meet through stringent quality control processes and Computer Numerical Control (CNC) machines. As a result, they are very durable and reliable for the long term.