Rotary screw air compressors are perfect for the following group of people and applications:
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But there are many situations where various businesses opt for rotary screw air compressors in places where reciprocating air compressors can work better. If any of the following applies to your projects, then you do not need a rotary screw air compressor:
In the above cases, you can go for a reciprocating air compressor to get the work done in the best of ways.
Choosing the right capacity and pressure for a new rotary screw air compressor.It is essential to consider the right air compressor that can supply enough amount of compressed air at the right pressure to power all your tools. Unfortunately, most people do not know their requirements and end up buying too big or too small air compressors.
So, this section will help you in that respect. If you opt to buy a rotary screw air compressor, it should be for the following reasons.
1. It is your first air compressorCheck your user manual and specification sheets of the pneumatic equipment. This part should tell you the right pressure at which your air tools operate and the capacity you need. The components that require the highest pressure will dictate the pressure requirement. You should also add 1.5 bar to the minimum pressure required to account for any pressure drop and load-unload differential of your rotary air compressor.
After that, you should add up the air consumption of all your air tools. This should be the capacity of your air compressor. It is essential to buy a bigger air compressor, but not too big. Rotary screw air compressors do not like standing still. You should keep in mind that some air tools come with average consumption rating while others state the maximum consumption rating.
2. It is a replacement for an old rotary air compressor.You should check the capacity and pressure of your old rotary air compressor.If the old air compressor you had was adequate, you should buy a new air compressor of the same pressure and capacity. You should take a moment to decide whether it is the right choice to get a slightly bigger air compressor to account for future consumptions.
3. You have a reciprocating air compressor and need more capacity (cfm).You should check the pressure of the current air compressor. Ignore the maximum pressure rating of a reciprocating air compressor since it is often higher than what is needed to operate your air tools.
If you want a replacement for your air compressor, you should check the capacity of the current air compressor. Now you understand that you should buy a slightly bigger air compressor than the current one. How big? This one depends on the type of air tool and equipment you added to the business that made you opt to get another air compressor. You should also keep in mind that your business can expand in the future.
If you want a replacement to your old air compressor, you should keep in mind that a rotary screw air compressor does not like standing still as it will likely be old and rusty. In this case, you have to ensure that your rotary air compressor is the primary compressor, while your reciprocating air compressor becomes the secondary compressor. Rotary screw air compressors are the most energy-efficient.
4. You have a rotary screw air compressor and need more capacity.Most of the time, people tend to buy the same type of air compressor as the one they already have. This is an excellent idea because it allows you to use the two air compressors side by side or use one as a backup for the other. Another great idea is buying a slightly bigger air compressor and use the old one as an emergency back up option.
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Is a rotary screw air compressor right for you? Screw compressors are the workhorses of industry and manufacturing. These tough industrial air compressors are widely used for applications requiring high efficiency and continuous airflow, including conveyor systems, manufacturing equipment, process manufacturing, and more.
Our complete guide to rotary screw compressors will help you understand how these compressors work and decide whether a screw compressor is the right choice for your application. Plus, how to install and maintain your compressor system for optimal performance.
A rotary screw air compressor (sometimes called a twin-screw compressor) is a type of air compressor that uses a pair of enmeshed helical screws to compress air. As the screws turn, the air is continually compressed. Screw air compressors are widely used for applications that require high CFM (Cubic Feet of air per Minute) and continuous use. This is the most commonly used air compression technology for heavy industrial applications such as powering pneumatic production lines and conveyor systems.
They can be contrasted with a reciprocating air compressor, which uses pistons driven by a crankshaft to compress air.
Read more: Reciprocating vs. Rotary Screw Air Compressors: Whats the Difference?
A rotary screw air compressor works by forcing air through a pair of rotating helical
screws (or rotors). The two rotors interlock as they turn, creating a series of chambers. As air is forced through the rotors, it is squeezed into a smaller volume. This reduction in volume compresses air as it moves the chambers. A rotary screw air compressor is a form of positive displacement compressor. The compression process is continuous and controlled by a drive motor and a system of inlet and discharge valves.
There are two basic kinds of rotary screw air compressors: oil-injected and oil-free. Oil-injected screw compressors are the most common type of industrial air compressor and work well for most applications. Within these categories, there are also some subtypes to consider.
Read more: Why Choose or Upgrade to a Variable Speed Drive Air Compressor?
An oil-injected (or oil-flooded) rotary screw air compressor uses oil to lubricate the screw unit and ensure its smooth operation. The oil also helps to cool the compressed air and prevent overheating of the unit. After the air is compressed, the oil is removed using an oil separator. A small amount of oil may be left in the compressed air (oil carryover), which can be further reduced using inline filtration.
An oil-free (or oil-less) rotary screw air compressor uses a two-stage compression process. Air passes through an intercooler between compression stages to bring temperatures down and prevent overheating. Oil-free rotary screw air compressors eliminate any oil carryover, producing very clean air. However, they tend to be more expensive, more complicated to maintain, and noisier than their oil-injected cousins. Oil-free screw compressors are most commonly used for specialty applications requiring very high-purity air. However, in most cases, it is possible to obtain the required purity levels using dryers and air filtration.
Read more: Do You Need an Oil-Free Compressor? Probably Not.
These are the basic components of a rotary screw air compressor.
The air-end is where the work of air compression happens inside the rotary screw air compressor. The air-end consists of several component parts.
A rotary screw air compressor must have several other components in addition to the air-end.
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Read more: How to Adjust the Air Compressor Regulator.
Filters keep contaminants out of the air supply. Filters for a rotary screw air compressor may include:
Read more: What Type of Filtration Does Your Air Compressor Need?
Rotary screw air compressors generate a lot of heat during compression. This heat must be dissipated by a cooling system to prevent overheating. An aftercooler acts as a heat exchanger, absorbing heat from the compressed air and carrying it away where it can be dissipated. The aftercooler cools air and removes the majority of the moisture before it goes into the drying system and filters. There are two basic types of air compressor after-coolers: air-cooled and water-cooled.
Most screw compressors are air-cooled. Air-cooled rotary screw compressors use a series of coils that are cooled by a fan. Cooling fins provide additional surface area for air to move across, increasing the heat transfer capacity.
Water-cooled rotary screw compressors use water (or, sometimes, another liquid) to carry away excess heat. Water-cooled aftercooler system options include:
An oil-injected (or oil-flooded) rotary screw air compressor will have additional components as part of the oil injection system.
A complete compressed air system will include a number of other components in addition to the air compressor itself.
Hot, compressed air coming out of the air compressor will contain excess moisture. For most applications, it is desirable to remove moisture from compressed air to ensure a supply of clean, dry air for industrial processes. There are two basic types of compressed air dryers.
Read more: Refrigerated vs. Desiccant Air Dryers How to Choose a Compressed Air Dryer.
The air receiver tank (or compressed air storage tank) stores compressed air after it leaves the air compressor. The air receiver tank may be placed either before or after the air drying system.
Read more: Air Receiver Tank Full Guidelines
Drain valves are used to remove excess liquid water from the compressed air system. When compressed air comes out of the rotary screw air compressor, it is very hot and hot air can hold more moisture than cold air. As the air cools back down to atmospheric temperatures, excess liquid will fall out of the air as condensation. Drain valves are used to drain excess liquid out of the air compressor, air receiver tanks, air dryers, compressed air piping, and other parts of the system where liquid may accumulate.
Before selecting a rotary screw air compressor, make sure it is the right choice for your application. Here are five important questions to ask when making your decision.
Rotary screw air compressors are especially durable and are able to handle large amounts of demand for extended periods of time. They are still more efficient and durable than piston compressors, even at smaller sizes, but the efficiency benefits are most noticeable when getting into larger demands (i.e., 15 HP and more). Rotary screw air compressors are designed to run at 100% duty cycle, day in and day out.
While a rotary screw compressor may have higher air compressor maintenance costs and/or initial capital costs, its life expectancy is much greater than a piston-type air compressor. Piston-type (reciprocating) compressors typically last about 10,000 - 20,000 hours before a rebuild is necessary. On the other hand, a rotary screw compressor will last between 80,000 - 100,000 hours. Rotary screw compressors are known for their reliability and longevity.
Rotary screw air compressors are known for their quiet operation. Since most rotary screw air compressors come standard with sound-dampening enclosures, they generally operate between 65 75 dBA, which is much lower in comparison to other types of compressors. For comparison, a reciprocating or piston-type air compressor can operate at around 80 85 dBA.
Rotary screw air compressors are designed to have no more than 3 PPM of oil carryover, while piston compressors can have 10 PPM or more as they age. Less oil carryover means that you have to change your filter elements less often, therefore decreasing compressor maintenance costs.
Rotary compressors have become more and more popular because of their efficiency and their ability to keep up with constant high demand. Many rotary screw compressors are used 24/7.
Even if you dont have a constant demand, rotary screw reliability, and durability come in a variable-speed drive version. A VSD compressor will speed up and slow down in relation to your demand at any given moment. This option should definitely be considered if your demand varies, because yesterdays controls including online/offline, modulation, and even turn valves have proven to be costly when compared to the benefits of a VSD.
Rotary screw air compressors are the most popular type of air compressor for industrial applications and for good reason. These air compressors are the workhorses of the industry: reliable, quiet, energy-efficient, and powerful. They are an excellent choice for high-volume applications requiring a continuous supply of air.
Rotary screw air compressors are used across many industries that require high CFM or continuous airflow (100% duty cycle), including manufacturing, food processing, pharmaceuticals, processing plants, paint lines, packaging lines, and much more. These industry staples provide a reliable source of compressed air for many applications in manufacturing and industry, from powering equipment to pneumatic conveying, to process air.
Read more: Top 10 Industrial Compressed Air Applications.
Many manufacturing facilities rely on screw compressors to power production equipment, conveyors, and packaging lines. Rotary screw compressors provide consistent airflow and pressure for robotic production applications in manufacturing sectors such as automotive, aerospace, and general fabrication. Manufacturing plants also use compressed air to lift and move heavy parts and power manual tools. Other applications in manufacturing include:
Process industries, including chemical manufacturing and pharmaceutical manufacturing, rely on rotary screw compressors for both process air and to power machinery and conveyors. Air for pharmaceutical and process industries may need to meet very strict standards for purity. Screw compressors can be used to power applications such as:
Food and beverage manufacturers may use screw compressors in a variety of ways, from product blow-off and cleaning to packaging lines. A rotary screw compressor provides consistent and reliable air for food and beverage applications, including:
While small family farms may be more likely to use a reciprocating or piston compressor, large-scale commercial farming can benefit from the high efficiency and high CFM of a rotary screw compressor. Applications for screw compressors in farming include:
Rotary screw compressors are widely used throughout the energy sector for a variety of purposes. In the oil & gas industry, screw compressors are used to power drilling equipment and pneumatic systems for transporting drilled oil. Compressed air may also be used to power equipment for compressing natural gas and refining petroleum. Other uses in the energy sector include:
What kind of maintenance is required for a rotary screw air compressor? Rotary screw air compressors require regular inspection and maintenance to operate at peak performance and protect the system from excessive wear and tear. Check your owners manual for specific guidelines for your make and model of rotary screw air compressor. Air compressor maintenance tasks may include:
Read more: Maintaining Your Air Compressor.
Checking and changing the oil is one of the most important maintenance tasks for an oil-injected rotary screw air compressor. Depending on your compressor model and the type of oil used, you can expect to change the oil every 4,000 8,000 hours. However, if your rotary screw air compressor is operating in a dirty environment, the oil may need to be changed more often. Check oil levels and inspect oil for contaminants at least weekly. At least once a year, oil should be completely drained and flushed. Always replace your oil filter after flushing.
Air compressor filters (including air intake filters and inline filters) should be changed at a minimum every 2,000 hours for a rotary screw air compressor. If your environment is very dirty, you may need to change filters more often.
Water should be drained for a rotary screw air compressor at least daily, if not more often. To reduce maintenance time, look for automated drain valves. Electric drain valves can be set to open on a timer to drain condensate regularly. A zero-loss drain valve uses a float mechanism to activate the drain, so it only opens when needed. This can reduce compressed air loss.
Proper compressor installation is very important for a screw compressor. There are several factors to consider for installation of a rotary screw compressor.
The experts at Fluid-Aire Dynamics can help you select the best rotary screw air compressor for your application. Choosing a rotary screw air compressor depends on your airflow requirements, production processes, and budget. Contact us for help in choosing the best compressor for your needs.
All in all, rotary screw compressors today have become popular because of their efficiency, noise level, and the fact that the cost for this type of compressor has dropped significantly in the last ten years. They have low oil carryover and are durable and reliable. They come in VSD for applications with varying demands throughout the day. Rotary screw compressors are a worthwhile investment for any manufacturer looking for a good quality, overall cost-effective unit.
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