Introduction
When most people think about air compressors, they picture piston air compressors as the primary or traditional design. These machines have been around for decades, and they are known for being relatively inexpensive.
A piston air compressor operates by physically pushing air into a small space using pistons. It then collects the compressed air in a receiver tank.
However, in the current market, we already have a new and improved type—the rotary air compressor.
Despite being more expensive than piston air compressors, these more advanced variants come with numerous benefits. These features make rotary air compressors a great choice for various industries around the world.
What is a Rotary Compressor in the Philippines?
A rotary compressor is a type of compressor that uses either a rotary screw air end or a rotary scroll air end. This variant also has four types based on their rotor design: the screw, lobe, vane, and scroll. Unlike piston air compressors that need large volumes of high-pressure air, a rotary compressor’s process is a continuous sweeping motion, so there is minimal pulsation or surging of flow. Aside from that, rotary air compressors are a lot quieter and produce cooler air that is easier to dry.
Rotary compressors have been popular since the 1980s, with the twin as the most common type. In this variant, two mated rotors mesh together to trap air and reduce the air volume along the rotors. These units are usually used in sizes ranging from 5 to 900 HP and are available as lubricated or oil-free, depending on the air purity requirements.
Currently, rotary air compressors are the industry standard in plant air compressors. They vary from about 25 to 300 HP and are expanding into smaller and larger markets.
Here are the advantages of using rotary air compressors:
⦁ Rotary air compressors can operate continuously and experience little to no downtime with their nonstop airflow and pressurization. They generate less heat and do not have to cycle off to maintain the machinery.
⦁ The design of rotary air compressors drives down maintenance costs whilst effectively function at high speed and handle large quantity of fluid.
⦁ Rotary air compressors have extremely high airflow rates, making them efficient for running heavy tools and equipment.
⦁ This type of air compressor can operate in extremely high temperatures.
What are the Components of a Rotary Compressor?
Before knowing how rotary air compressors work, you need to identify their different components. These parts are the following:
Air end
The heart of all air compressors. This is the part of a rotary air compressor in which the air is compressed. During this process, air enters the air end through an inlet valve where it is mixed with oil.
Air filter
This component is essential as it affects the longevity of the rotary compressor. The air filter must be suited to the environment and the required airflow. This can also be mounted directly to the compressor. For remote mounting, it can be connected with an air intake hose.
Primary separator tank
This acts as an oil reservoir used as a defense mechanism against oil and gas mixture. When compressed air leaves the air end, it is mixed with compressor oil. This mixture will enter the primary separator tank where the first separation of oil will happen.
The primary separator tank utilizes mechanical separation and centrifugal force to drive oil molecules together. This process will form droplets that will fall to the bottom of the tank, and the oil amount will then be removed from the air.
Secondary separation filter
Also known as coalescing filter, this component includes a membrane material that gathers all remaining oil particles and circulates them back into the main oiling system. This separation filter can be attached to the primary separation tank or mounted on its filler manifold remotely.
Oil filter
This part is essential due to the rotary air compressor’s closed-loop oiling system. The oil filter is responsible for collecting any loose particles that have been collected in the oil, which should not re-enter the rotary air compressor.
Oil cooler
This can be used together with the engine’s cooling system, or it can be a stand-alone air-to-liquid cooler. The process of air compressing generates a lot of heat, which warms up the oil. This heat must pass through a cooler before it is circulated back to the compressor.
The oil cooler has a liquid-to-liquid version that needs a sufficient cooling capacity to lower the temperature of the compressor oil and the engine cooling. The air-to-liquid cooler, however, will need clean, cool air to keep the oil in its optimal temperature range.
Hoses
Hoses are necessary to transport oil and air between various air compressor components. This component must be able to handle the heat, pressure, and chemicals of the compressor oil. Incorrect hose selection can lead to early failure, which may be costly and dangerous.
Controls
A rotary compressor will either use mechanical or electrical controls in the form of a button, switch, or lever. These controls will switch on and off the rotary compressor and may also provide critical diagnostic or service information.
Oil
Because it has a wide range of critical functions, oil is an essential component of a rotary screw compressor. It lubricates the system, protects the components against wear, keeps the system cool, and aids in the trapping and removal of pollutants. Keep in mind that selecting the proper oil for your rotary screw compressor is important to ensuring performance and efficiency.
Encapsulated air ends
These are used in several rotary screw compressors. The component incorporates various parts within the metal casing of the air end, such as rotors, intake valves, and separators, into a handy container. Encapsulated air ends, on the other hand, are large and restricting, posing design issues for air compressor makers. When used incorrectly, they produce an awkward, rigid form that must be addressed immediately.
How Do Rotary Compressors Work?
The operation begins when atmospheric air reaches the inlet valve of a rotary screw compressor. The air is then sent through the system pressure line to a valve on the regulator. This applies pressure on the entire system. Through the rotors in the air-end, the air is mixed with oil and compressed.
The oil-mixed air will now escape the air-end via the air discharge hose and enter the primary oil separator tank, which will separate the majority of the oil. Once the air has been separated, it will pass through the second separation filters, which will capture any remaining oil mist in the air.
The mechanism will now expel oil-free air. This output will be gathered in the tank if an air receiver tank is used. Meanwhile, the oil is transferred to the oil cooler and chilled. After that, it will be sent through an oil filter, which will trap any leftover particles in the oil. Finally, the scavenge line returns the recycled oil to the air-end.
Types of Rotary Compressors
Rotary screw compressors are classified into two types: oil-injected compressors and oil-free compressors.
Oil-injected Rotary Screw Compressor
Oil-injected rotary screw compressors are often used for gas refrigeration and petroleum processing. The oil in this compressor type is used to lubricate and seal the rotors in the air-end. As a result, the rotors can generate high pressures fast and compress air in a single step.
The oil is then separated from the air before it departs the system and recycled back into the air-end for reuse. Thanks to the oil-injected rotary screw compressor, the systems may also produce high CFM and psi on a continuous basis. For more details on this type, check out the ARMSTRONG single screw compressor offered by Compresstech Resources.
Oil-Free Rotary Screw Compressor
An oil-free rotary screw compressor is used in industrial, manufacturing, or medical applications where no oil can enter the airflow. These include the packaging processes of foods or medicinal oxygen. This type of compressor is also more expensive since it must compress in two stages to get the same pressure as an oil-injected rotary screw compressor.
An oil-free rotary screw compressor can also be classified as dry or water-flooded. A dry-running screw compressor may run at extremely high speeds, typically at 20,000 RPM or more. To power the two air ends, a lubricated gearbox with a bull gear and high-speed pinion gears is used.
Water-flooded oil-free compressors are typically single-stage units. Water is used to both seal the compression chamber and absorb heat. However, due to its structure, bacterial growth can be a serious problem in this compressor.
To address this problem, most of these compressors now include a reverse osmosis water filtering system that changes the water on a regular basis. A great example of this compressor is the BOGE Screw Compressor, which is available at Compresstech Resources. You can check it out at our website to find out more.
Applications of Rotary Compressor
Because of their safe, energy-efficient, and high-output characteristics, rotary screw compressors have been employed in a variety of sectors. They produce a near-constant flow of regulated air streams that are limited by maximum temperatures and machine operating pressures when correctly handled.
The most prevalent industries that use rotary screw compressors are construction, manufacturing, agriculture, energy production, and HVAC (heating, ventilation, and air conditioning).
Construction
Rotary screw compressors have been utilized for a variety of tools and equipment in the construction industry. Depending on the construction work and required variable flow streams, they are commonly found in jackhammers, nail guns, and compactors.
Aside from that, these compressors may power other portable instruments since they provide a transportable power supply that does not overheat or spike abruptly. As a result, they are a crucial safety component in both indoor and outdoor construction sites.
Rotary screw compressors are the most efficient sources for bulk drilling, handling, and lifting tasks in the construction industry. They provide power to hundreds of equipment in a variety of industries, including infrastructure construction, road building, demolition, and commercial and residential developments.
Manufacturing
Because of its capacity to increase industrial productivity, rotary screw compressors have been widely used in the manufacturing industry.
Products in the manufacturing business, particularly in the food and beverage sector, must be contaminant-free and properly sealed. Manufacturing equipment that uses rotary screw compressors may provide a good seal on items while also powering conveyor belts, sprayers, presses, and packing tools.
This is also applicable for molding and shaping production. The stable and powerful air streams of rotary screw compressors enable forming, cleaning, and finishing high-quality product.
Agriculture
Farming activities require long days of operating heavy and costly machinery. Tractors, sprayers, pumps, and agricultural conveyors are examples of these equipment. They are all driven by rotary screw compressors.
Aside from farming, compressed air is used in modern agricultural systems such as dairy farm and greenhouse ventilation. It delivers consistent and clean air across various sections of the spaces.
Energy Sector
Dependable and quality drilling equipment is critical to the crew’s safety. Even the tiniest faulty component or stalling of the power supply might disrupt operations or endanger the entire team. During these situations, rotary screw compressors help in providing a power supply to oil drilling equipment.
Aside from oil extraction, additional rig operations need secure and regulated energy provided by rotary screw compressors. After all, they are distinguished by their spark-free delivery and consistent outputs, which are critical in operations as sensitive and remote as oil rigs.
Heating, Ventilation, and Air Conditioning (HVAC)
Rotary screw compressors have been essential to HVAC units’ air-sourcing and heat pump systems because they perform vapor compression refrigeration. This function refers to raising the temperature of the HVAC units and regulating the critical refrigerant cycles that indicate the cooling of the system. It also enables various HVAC units to have customized temperature adjustments.
Where to Buy Rotary Compressors in the Philippines?
Whether you’re planning to use rotary screw compressors for big industrial applications or to operate high-power air tools, Compresstech Resources Inc. has got you covered. We provide reliable and high-quality rotary screw compressors for sale at the most competitive rates.
Our wide range of rotary screw compressors feature a large output capacity and a compact, robust construction. They are also designed to provide constant airflow throughout 24-hour operations.
Here are the rotary screw compressors that we offer:
Armstrong Single-Screw Compressor
Oil contamination has been proven detrimental to a variety of applications, leading to the adoption of oil-free compressors in a wide range of industries, such as medical, research, food, and pharmaceuticals.
Fortunately, Compresstech provides Armstrong single-screw compressors. This compressor is built with water-injected compression technology, which ensures that no hydrocarbons are present in the air. It comes in fixed and variable speed variants with low operating temperatures.
BOGE Screw Compressor
This compressor is designed to work quietly and efficiently without the need for time-consuming maintenance. It is small and lightweight, and it can reach up to 270 horsepower. In addition, it has intelligent standard controls.
FS Curtis Screw Compressor
The FS Curtis screw compressor utilizes a 15kW TEFC motor for efficiency, as well as eCool technology for heat protection, thermal stress reduction, double engine life, and electric life. It includes a full voltage motor starter that complies with continuous work standards.
Ingersoll Rand Screw Compressor
The Ingersoll Rand screw compressor is customized to fit the needs of the customer. It has web-enabled controls for efficient system monitoring. This compressor also has a power range of 5 to 500 horsepower and may be used in either air-cooled or water-cooled systems.
Gardner Denver Screw Compressor
The Gardner Denver screw compressor is engineered to fulfill the demanding requirements of continuous operation in critical and industrial applications. It comes in oil-free and oil-flooded versions, with fixed or variable speed drives.
Conclusion
It’s difficult to overlook the diverse and critical applications of rotary screw compressors in various industries.
At Compresstech Resources Inc., we are fully dedicated to helping you find the right rotary screw compressor for your needs. Get in touch with us right now for more details.