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Screw Compressor

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What is Screw Compressor

 

A screw compressor is a type of positive displacement compressor that uses two spiral screws to compress the gas. It uses a positive displacement rotary mechanism for the compression of gas.

 

What are Advantages of Screw Compressor
 

 

High Efficiency and Energy Saving
Compared with other compressors, the exhaust temperature of screw compressors is low, which can better protect the stability of the compressed medium, thereby effectively improving the efficiency of the compressor and reducing energy loss. In addition, the screw compressor operates through the meshing of the twin screws, and the energy conversion of the compressed medium is relatively sufficient, which can better reduce energy consumption and improve the efficiency of the compressor.

 

Reliable and Stable
The screw compressor has a compact structure, fewer parts, less friction between the compressed medium and the compressor, and relatively less noise and vibration during operation. Therefore, it has higher stability during operation, lower failure rate, and longer service life.

 

Environmental Protection
Screw compressors can adapt to a wide range of compressed media, which is conducive to reducing energy consumption and emissions, meeting environmental protection requirements, and is also more sustainable.

 

What are the Applications of Screw Compressor

Air Compression

Screw compressors find extensive use in the field of air compression. They can compress a large volume of air into high-pressure gas, employed in industrial processes for power transmission, pneumatic tools, pneumatic control systems, and more.

 

Refrigeration and Freezing

Screw compressors are widely applied in the refrigeration and freezing sectors. By compressing the refrigerant into high-temperature, high-pressure gas, followed by cooling and condensing in a condenser, and subsequent expansion through an expansion valve, the refrigeration and freezing objectives are achieved.

 

Industrial Sector

In the industrial sector, screw compressors play a crucial role. For instance, in industries such as petroleum, chemicals, and power generation, screw compressors are utilized in processes like gas transportation, gas boosting, and gas circulation.

 

 

 
Process of Screw Compressor
 
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Raw Material Procurement
The manufacturing process of screw compressors requires the use of various materials, such as steel, copper, aluminum, etc. These materials need to be purchased through professional channels, and the quality of the materials needs to be confirmed by quality inspection.

02/

Parts Processing
The processing and production link is the core step in manufacturing screw compressors. In this step, the purchased raw materials need to be processed and formed to make various parts, including screws, compression chambers, inlet valves, outlet valves, etc.

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Assembly
After the parts are processed, they need to be assembled. Combine the various parts according to the design drawings to form a complete machine. This link needs to be strictly operated in accordance with the specifications to ensure the quality of each component to avoid failures in the later stage.

04/

Debugging
After the assembly is completed, the whole machine needs to be tested and debugged. Run it for a period of time to test the performance indicators of the screw compressor such as output gas flow and compression efficiency to ensure its normal operation. At the same time, adjust and optimize the machine according to the test results.

 

Components of Screw Compressor
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Rotor
The screws of the compressors are also known as rotors. A screw compressor has two rotors (male and female rotors) for the compression of the gas. The male rotor is connected with a shaft. As the shaft rotates, it also rotates the male rotor. The male and female rotors mesh with each other. The movement of these rotors plays an important role during the suction and compression of the gas. As the rotors start rotating, they suck the gas from the outside into the compressor. After suction, they further compress and discharge the gas.

 

Compression Cylinder
The compression cylinder of the screw compressor plays a vital part in the compression process. As the rotors start rotating, a vacuum is produced inside the cylinder; due to that, air or gas enters the compression cylinder. This cylinder has a decreasing volume from the inlet to the outlet. The male and female rotors rotate inside the cylinder.

 

Air Filters
The air filter is installed inside the inlet valve of the compressor. It stops air particles, dust, moisture, and other contaminations from entering the compressor. If this filter isn’t installed with the inlet valve, the contaminations may damage the internal parts of the compressor.

 

Inlet Valve
As the vacuum inside the rotary screw air compressor generates, the compressor sucks the gas through the inlet valve.

 

Outlet Valve
After increasing the desired pressure of the gas, the compressor uses an outlet valve to discharge the compressed gas.

 

Motor
An electric motor uses to supply power to the male rotor of the screw compressor. This motor is connected to the male rotor via a crankshaft. As the motor turns on, it turns the shaft which further rotates the male rotor.

 

Housing
The main objective of the housing is to prevent the internal components from any damage due to the fall of any external load. It acts as a safety guard for the inner parts of the compressor.

 

Bearings
The bearings are installed on both ends of the rotor. They help in the rotation of the rotor and increase the life cycle of the rotor. The main objective of the bearing is to balance the rotor blade and the rotation of the rotor.

 

How to Choose Right Screw Compressor

 

 

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Power and Capacity

One of the most crucial factors to consider while purchasing a screw compressor is its power and capacity. The electrical power and capacity of the compressor should align with your industry’s requirements regarding pressure and air volume.

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Quality

A high-quality compressor is typically made of robust, durable materials, offers excellent performance, and has a longer lifespan. Ensure the compressor you choose fulfills quality standards and comes with a warranty.

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Maintenance

Compressors with minimal maintenance needs can save time, effort, and costs, as well as enhance the overall efficiency of your operations.

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Noise Levels

As screw compressors are used in work settings, you should select a model that keeps the noise levels to a minimum to offer a conducive working environment.

 

Maintenance Tips for Screw Compressor
 

Regular Inspections
Regularly inspect and replace worn parts such as filters and separators. Air filters prevent contaminants from entering the compressor, while oil filters and separators ensure clean oil circulation. Replace these components according to the manufacturer’s recommended intervals or sooner if they appear dirty or clogged. Inspect the compressor’s piping, hoses, and fittings for any signs of wear, cracks, or leaks. Replace any damaged parts to prevent air leaks and ensure optimal performance.

 

Lubrication
Lubrication is essential for the smooth operation of screw compressors. The lubricant reduces friction, prevents wear, and helps dissipate heat. Use the correct type of oil recommended by the manufacturer, as using the wrong oil can lead to damage and void the warranty. Change the oil and oil filters at the intervals specified in the maintenance manual. Regularly check the oil level and top it up if necessary. Monitor the oil’s condition and look for any signs of contamination, such as discoloration or the presence of debris. If the oil appears dirty or degraded, replace it promptly. Proper lubrication not only extends the life of the compressor but also improves its efficiency and performance. Consider using high-quality lubricants specifically designed for screw compressors to ensure optimal performance.

 

Operational Checks
Perform routine operational checks to ensure settings like pressure and temperature are within normal ranges. Monitor the compressor’s gauges and control panel for any abnormal readings or warning indicators.

 

FAQ

Q: Why use a screw compressor?

A: Screw compressors are most commonly used because of their different advantages over other types of compressors, mainly for applications demanding continuous and high air demand. These benefits include very low maintenance requirements, easy design, very low vibrations, lower noise levels, and higher efficiency at full load. The rotary compression mechanism in a screw compressor permits it to work continuously and smoothly.

Q: Which oil is used in the screw compressor?

A: The oil used in a screw compressor usually varies according to the screw compressor type and its application. Synthetic or mineral lubricants are most commonly used to ensure smooth working, minimize friction between the rotors, and offer efficient heat dissipation.

Q: How does a screw compressor work?

A: A screw compressor works with a male and female rotor that rotates in the opposite direction. This movement draws in air that is compressed as the space between the rotors and their housing decreases. The compressed air is then displaced to the outlet. Each screw element has a fixed, built-in pressure ratio dependent on the length and pitch of the screw. As well as the form of the discharge port. To attain maximum efficiency, the built-in pressure ratio must be adapted to the required working pressure. The speed of the rotors is optimized at a certain level to minimize mechanical losses (due to heat at very high speed) and volumetric losses (air losses due to very low speed).

Q: What are the disadvantages of screw compressors?

A: Cost: Due to their more advanced design, screw compressors often cost more than their piston counterparts.
Intermittent Loads: The rotating, continual motion of a screw compressor is perfect for continual use, but it is not ideal for intermittent loads. Stopping and starting a screw compressor regularly can cause issues in some circumstances.
Maintenance: Although maintenance is less frequent for a screw compressor, it can also be more complicated. If something does need to be repaired, this can often result in the need for reassembly and alignment of the screw shaft. Screw compressors require precision performance, and so qualified technicians are preferential for such maintenance work.

Q: What should be paid attention to when installing a screw compressor?

A: Installation site
When installing a screw compressor, you need to choose a well-ventilated, dry, dust-free, vibration-free, and corrosion-free site for installation. At the same time, you must also pay attention to preventing noise from affecting the surrounding environment. If you must install it in a residential area, you need to take necessary sound insulation measures.
Foundation design
The foundation must be strong enough to withstand the weight and vibration of the compressor, and prevent problems such as foundation settlement or cracks.
Pipeline system
The layout and installation of the pipeline system must meet the design requirements, and there must be no bending, flattening, or obstruction of airflow. During the installation process, attention should be paid to pipeline balance, and all jacking pipes, hosting pipes, and hanging brackets should be carried out according to the design requirements. The connection method in the gas system should comply with relevant specifications, and quality inspection should be strictly implemented.
Cooling system
The design of the cooling system should be determined according to the use environment and model of the compressor, and should meet the requirements.
Electrical wiring
The electrical wiring of the screw compressor should be installed firmly, the terminal should have good contact, and the cable should meet the relevant standards. Before electrical wiring, it is necessary to determine whether the power supply voltage and frequency meet the electrical requirements of the compressor, and check whether the relays, circuit breakers, protective devices, etc. are installed properly.

Q: Can screw compressors be used in heavy-duty industrial applications?

A: Yes, screw compressors are well-suited for heavy-duty applications. They are capable of non-stop operation, offer high capacity and efficient heat dissipation, and are designed to be durable and long-lasting, even in the demanding conditions of large-scale industrial environments.

Q: How do screw compressors contribute to sustainability and energy efficiency?

A: Screw compressors significantly reduce energy consumption, which in turn lowers carbon emissions. Their durable design minimizes waste and the need for frequent replacements, making them an environmentally friendly choice for industries committed to sustainability.

Q: How to improve the service life of screw compressors?

A: Keep it clean: Screw compressors are widely used and are usually in high temperature, high pressure, corrosive and polluted environments. Long-term work will cause dust to accumulate on the surface of the equipment, and may even cause the internal parts of the equipment to rust, reducing the working efficiency of the equipment. Therefore, it is important to clean the surface of the equipment regularly, and you can use a cleaning agent to thoroughly clean the equipment.
Replace the filter element: The screw compressor also needs to replace the air filter element and oil filter to ensure that the equipment achieves better performance and long life.
Check the connection: Keep the equipment pipeline connection stable and have good sealing performance, whether in operation or transportation. During regular maintenance, check whether the sealing of each interface, nut and connecting pipe is good.
Check the electronic control system: The electronic control system of the screw compressor plays a vital role in operation. Therefore, maintenance personnel should regularly check the electrical components of the equipment, such as wires, electrical sockets, switches, touch screens, etc., to ensure the normal operation of the equipment.
Regular lubrication: Lubricating the screw compressor can greatly extend its service life. Correct use of lubricants and setting lubrication cycles can reduce wear and friction of the equipment and ensure the normal and efficient operation of the equipment.
Regular spare parts replacement: For some wearing parts, regular spare parts replacement is recommended to reduce the risk of downtime due to damage. Before replacing spare parts, it is necessary to ensure that the new parts meet the standards and regulations with the original parts, and replace them as required.

Q: Why does a screw compressor need lubrication?

A: Lubrication means that when the machine is running, a lubricating film is formed between the machine parts to reduce friction and wear between the machine parts, thereby reducing energy loss and improving machine efficiency. In a screw compressor, the lubricant can form a sliding lubricating film between the friction parts inside the machine, thereby reducing direct contact between the machine parts, reducing machine part loss and noise. The principle of lubrication is to use the viscosity of the lubricating oil to form a stable lubricating film, reduce friction, reduce energy loss, and take away friction heat to avoid overheating of the machine and wear of the machine parts. Generally speaking, the lubricating oil should have good heat resistance, oxidation resistance, corrosion resistance, wear resistance and other properties, and needs to be replaced regularly.

Q: Why does the screw compressor need cooling?

A: Cooling means lowering the internal temperature of the screw compressor through a cooling device to ensure the normal operation of the machine. Inside the screw compressor, after the compressed gas is compressed multiple times, the stored energy also increases, causing the temperature of the screw compressor to continue to rise. If it cannot be cooled in time, it is easy to cause damage to the machine. The principle of cooling is to use a refrigeration device to take away the heat inside the compressor through heat transfer to ensure the normal operation of the machine. Generally speaking, there are two main cooling methods: air cooling and water cooling.

Q: How many lubrication methods are there for screw compressors?

A: For screw compressors, there are two main lubrication methods: dry and wet. Dry lubrication means that during the compression process, the screw surface is not protected by a lubricating oil film, but is lubricated by bearings, gears and other components; wet lubrication is to spray lubricating oil into the screw compression chamber to form a lubricating oil film to protect the screw surface.

Q: How to choose lubricating oil?

A: Generally speaking, screw compressors are lubricated with lubricating oil. The selection of lubricating oil needs to consider multiple factors, such as machine model, pressure, temperature, oil selection and other factors. Different compressors need to choose different lubricating oils to ensure the normal operation and life of the compressor. At the same time, after long-term use of different compressors, the lubricating oil also needs to be replaced regularly.

Q: What is the reason for the high volumetric efficiency of screw compressors when they are working?

A: A screw compressor is a centrifugal compressor that compresses gas to a higher pressure by meshing two rotating screws with each other. Compared with other types of compressors, it has the advantages of simple structure, high compression ratio, smooth operation, low noise, and high volumetric efficiency. Specifically, the high volumetric efficiency of screw compressors is mainly due to the use of oil-swinging technology and plane closed structure. Oil-swinging technology can produce a thin oil film at the screw meshing point, which can not only protect the machine from wear, but also effectively reduce leakage losses and improve compression efficiency. The plane closed structure can reduce the chance of gas leakage, and at the same compression ratio, a higher volumetric efficiency can be obtained.
The screw compressor adopts a continuous compression method. This means that during the rotation of the screw, the gas is always in a compressed state, and there will be no intermittent compression and deflation. Compared with the intermittent compression method, the screw compressor can improve the volumetric efficiency while maintaining a relatively high compression ratio, saving energy and reducing emissions. In addition, the speed range of the screw compressor is relatively wide and can be adjusted as needed. When a higher volumetric efficiency is required, a lower speed can be used; when a higher compression ratio is required, a higher speed can be used. This also enables the screw compressor to be adjusted according to different needs and improve its volumetric efficiency.

Q: What factors affect the efficiency of screw compressors?

A: Blade shape
The blade shape design of the screw compressor has a great influence on the efficiency of the compressor. The blade shape can effectively perform critical transition, gas transfer and compression on the gas.
Inlet and outlet pressure difference
The greater the inlet and outlet pressure difference of the screw compressor, the higher the efficiency. However, excessive inlet and outlet pressure difference can also cause excessive wear and overload of the equipment.
Rotor speed
The rotor speed has a great influence on the efficiency and energy consumption of the screw compressor. Reasonable rotor speed can optimize the efficiency of the screw compressor.
Temperature and humidity
The ambient temperature and humidity will affect the efficiency of the screw compressor. For these changes, the user should adjust the speed and output pressure of the equipment according to the actual situation to achieve the best efficiency.

Q: How to calculate the efficiency of a screw compressor?

A: The efficiency of a screw compressor is generally measured by two indicators: pressure ratio and adiabatic efficiency. The pressure ratio refers to the ratio of the outlet pressure to the inlet pressure, and the adiabatic efficiency refers to the theoretical maximum efficiency without heat dissipation during the compression process.

Q: What factors affect the exhaust temperature of a screw compressor?

A: Compressor inlet temperature: The higher the inlet temperature, the higher the heat generated during the gas compression process, which leads to an increase in the exhaust temperature.
Compressor load rate: The higher the load rate, the higher the exhaust temperature of the compressor.

Q: What is the screw compression ratio?

A: The screw compression ratio refers to the ratio of the gas pressure at the inlet to the gas pressure at the outlet when the screw compressor is working. It is an important parameter to describe the working state of the screw compressor.

Q: What is the impact of the compression ratio of the screw compressor on the operation of the machine?

A: If the compression ratio is too large, the power required by the compressor will increase; and high-temperature and high-pressure air is prone to cause machine failures such as lubricant decomposition and valve wear. Therefore, in actual use, the appropriate compression ratio of the screw compressor should be determined according to the specific situation to achieve the best operating state.

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