Nowadays, people can find Compressed air everywhere - in homes and factories worldwide, serving various industries. With so many uses for compressed air, it's no surprise that there are many different compressor types.
Let's take a closer look at rotary screw air compressor technology! In this article we will answer the following questions:
- What is a screw compressor?
- What are the main benefits of a screw compressor?
- What is the basic working principle of a screw compressor?
- What essential parts make up a screw compressor?
- Where are screw compressors used?
- What is the difference between a piston and screw compressor?
- Is there a screw compressor solution for me?
Screw Element
The screw element was created in the 1930s. It has two parts, a male and a female rotor.
In oil injected screw compressors, the male rotor powers the female rotor. In oil-free compressors, a timing gear drives both rotors. The rotors work together smoothly with very little space between them.
Thinking of investing in a rotary screw compressor? Here are some benefits you can expect:
- Higher reliability
- Energy efficiency
- 100% duty cycle
- Low noise output
- Small footprint
- Continuous operation at temperatures of up to 46°C (55°C optional)
- Low oil carry-over (as little as 3 ppm) in oil-lubricated machines
- Zero loss of capacity over time
A screw compressor works by having two rotating parts that draw air in between them because they move in opposite directions. As the air moves through the rotors, it compresses the space between them, resulting in compressed air. This process generates compressed air and pushes it our through the outlet. The rotors are set an ideal speed to reduce mechanical and air losses caused by high and low speeds respectively.
When purchasing a screw compressor, it's crucial to know the necessary components for a well-functioning rotary screw air compressor. Here is a quick list of the essential parts and functions:
- Rotary screw element - Drives the air to the outlet and creates the pressure.
- Compression chamber - Encloses the rotary screw element. It's possible to have multiple stages for more pressurisation.
- Inlet suction air filter - Set at the inlet of the compression chamber where it's possible to catch and reduce dust and ingress of damaging particles. Necessary for cleaning and protection of the compressor stage/s.
- Oil filter - Oil filters remove dirt and impurities from the oil used for lubrication or compression in the oil system.
- Anti-friction roller and ball bearings - These secure the rotary screws, making sure they are balanced and rotate evenly.
- Suction valve or load/unload valve - The compressing unit usually sets this at the top. The rotary screw element processes the raw air drawn inward. When the pressure in the system is too low, it opens completely. On the other hand, when the pressure is too high, it closes the valves.
- Discharge valve - The compression process usually sets this at the end. It opens when it reaches the right pressure and maintains enough pressure for proper lubrication of the compression stages.
- Compressor motor - This drives the rotary screws and powers the unit's compression cycle. The compressor microprocessor controller controls it.
- System control - This takes the form of a display and input panel. Necessary for operating, automating and monitoring the compressor unit.
- Separator vessel - This tank separates oil from compressed air. It also acts as a reservoir for oil and maintains air pressure in the system using a pressure valve.
- Separators - The filter in the separator vessel of oil-injected compressors removes excess oil. This ensures that the compressed air has minimal oil content when it exits the system.
- Gaskets and seals - Necessary to maintain maximum pressure and make sure the overall compressor is leak-free at critical points in the unit.
- Non return valve/check valve - This valve keeps the pressure in the downstream system when the compressor stops generating air.
- After cooler - This cools down the compressed air and removes the heat generated by the compression process. The coolers can be either cooled by ambient air or with water cooled compressors. Customers select either air cooling or water cooling based on their individual requirements and the location of the installation.
- Water separator - The water separator is an important part of a screw air compressor. We place the moisture separator after the after coolerto remove liquid moisture from the compressed air. This ensures that the air leaving the compressor is completely free of any liquid water.
Take a peak inside an Atlas Copco screw compressor
Screw compressors are available almost everywhere compressed air is used, thanks to their many benefits. Just some of the industries you will find them in include:
- Transportation
- Food and beverage
- Medicine and health
- Mining
- Textile
- Construction
A screw compressor is different from a piston compressor because it doesn’t have valves and doesn't create unbalance. This allows it to work quickly and move a lot of air while still being small in size.
One of the reasons for the great popularity of rotary compressors is their versatility. There really is the right rotary compressor for every application. We offer screw compressors with three types of drives, each with their own benefits.
Belt Drive
These compressors are very robust as well as easy to install and maintain. In addition, they have the lowest initial investment cost among rotary screw compressors. This combination makes them a great choice for smaller operations.
Gear Drive
A gear drive makes compressors quieter. The investment is higher than a belt drive but also more energy efficient. Therefore, if you use the compressor a lot, this investment will pay off over time thanks to energy savings.
Direct Drive
This is the optimum of rotary compressor technology. The innovative direct drive offers unmatched efficiency and performance. Among the three, they create the least noise.
These are various types of direct drive rotary screw compressors. These compressors range from basic designs for smaller models to those with highly efficient variable speed drives.
High quality solutions for all
No matter what you need a compressor for, you can rest assure that a great solution is out there for you. If you're still unsure about the right screw compressor for you, you have two options. First you can continue searching on our website. Alternatively, you can reach out to one of our representatives on 1800 023 469.
Our representatives are knowledgeable and provide expert advice. They can also discuss our top products with you.
