Rotary-screw compressor
A rotary-screw compressor is a type of gas compressor, such as an air compressor, that uses a rotary-type positive-displacement mechanism. These compressors are common in industrial applications and replace more traditional piston compressors where larger volumes of compressed gas are needed, e.g. for large refrigeration cycles such as chillers, or for compressed air systems to operate air-driven tools such as jackhammers and impact wrenches. For smaller rotor sizes the inherent leakage in the rotors becomes much more significant, leading to this type of mechanism being less suitable for smaller compressors than piston compressors.
The screw compressor is identical to the screw pump except that the pockets of trapped material get progressively smaller along the screw, thus compressing the material held within the pockets. Thus the screw of a screw compressor is asymmetrical along its length, while a screw pump is symmetrical all the way.
The gas compression process of a rotary screw is a continuous sweeping motion, so there is very little pulsation or surging of flow, as occurs with piston compressors. This also allows screw compressors to be significantly quieter and produce much less vibration than piston compressors, even at large sizes, and produces some benefits in efficiency.
Working
Rotary-screw compressors use two very closely meshing spiral rotors to compress the gas. In a dry-running rotary-screw compressor, timing gears ensure that the male and female rotors maintain precise alignment without contact which would produce rapid wear. In an oil-flooded rotary-screw compressor, lubricating oil bridges the space between the rotors, both providing a hydraulic seal and transferring mechanical energy between the rotors, allowing one rotor to be entirely driven by the other.Gas enters at the suction side and moves through the threads as the screws rotate. The meshing rotors force the gas through the compressor, and the gas exits at the end of the screws. The working area is the inter-lobe volume between the male and female rotors. It is larger at the intake end, and decreases along the length of the rotors until the exhaust port. This change in volume is the compression.
The intake charge is drawn in at the end of the rotors in the large clearance between the male and female lobes. At the intake end the male lobe is much smaller than its female counterpart, but the relative sizes reverse proportions along the lengths of both rotors until the clearance space between each pair of lobes is much smaller. This reduction in volume causes compression of the charge before being presented to the output manifold.
The effectiveness of this mechanism is dependent on precisely fitting clearances between the spiral rotors and between the rotors and the chamber for sealing of the compression cavities. However, some leakage is inevitable, and high rotational speeds must be used to minimize the ratio of leakage flow rate over effective flow rate.
In contrast to Roots blowers, modern screw compressors are made with different profiles on the two rotors: the male rotor has convex lobes which mesh with the concave cavities of the female rotor. Usually the male rotor has fewer lobes than the female rotor, so that it rotates faster. Originally, screw compressors were made with symmetrical rotor cavity profiles, but modern versions use asymmetrical rotors, with the exact rotor designs being the subject of patents.
Size
The capacities of rotary-screw compressors are typically rated in horsepower, Standard Cubic Feet per Minute * and pounds per square inch gauge For units in the 5 through 30 HP range the physical size of these units are comparable to a typical two-stage compressor. As horsepower increases, there is a substantial economy of scale in favor of the rotary-screw compressors. As an example, a 250 HP compound compressor is a large piece of equipment that generally requires a special foundation, building accommodations and highly trained riggers to place the equipment. On the other hand, a 250 HP rotary-screw compressor can be placed on an ordinary shop floor using a standard forklift. Within industry, a 250 HP rotary-screw compressor is generally considered to be a compact piece of equipment.Rotary-screw compressors are commonly available in the 5 through 500 HP range and can produce air flows in excess of 2500 SCFM. While the pressure produced by a single-stage screw compressor is limited to 250 PSIG, a two-stage screw compressor can deliver pressures of up to 600 PSIG.
Rotary-screw compressors tend to be smooth running with limited vibration, thus not requiring a specialized foundation or mounting system. Normally, rotary-screw compressors are mounted using standard rubber isolation mounts designed to absorb high-frequency vibrations. This is especially true in rotary-screw compressors that operate at high rotational speeds.
History
The screw compressor was first patented in 1878 by Heinrich Krigar in Germany, however the patent expired without a working machine being built.The modern helical lobe screw compressor was developed in Sweden by Alf Lysholm who was the chief engineer at Ljungstroms Angturbin. Lysholm developed the screw compressor while looking for a way to overcome compressor surge in gas turbines. Lysholm first considered a Roots type blower but found this was unable to generate a high enough pressure ratio. In 1935, Ljungstroms patented a helical lobe screw compressor which was then widely licensed to other manufacturers. Ljungstroms Angturbin AB was renamed Svenska Rotor Maskiner in 1951.
In 1952, the first Holroyd cutting machine was used, by the Scottish engineering company Howden, to produce helical lobe compressor rotors greatly reducing both cost and manufacturing time.
In 1954, Howden and SRM jointly developed the first oil flooded screw compressor. Flooding provided both cooling, which allowed higher pressure ratios, and the elimination of timing gears. The first commercially available flooded screw air compressor was introduced in 1957 by Atlas Copco.
Slot valves were developed by SRM in the 1950s, allowing for improvements in capacity control which had been a limiting factor for screw compressor application.
Asymmetric rotors were first patented by SRM and subsequently introduced commercially by Sullair in 1969. The introduction of asymmetric rotors improved sealing, further increasing the types efficiency.
Applications
Rotary-screw compressors are generally used to supply compressed air for larger industrial applications. They are best applied in applications that have a continuous air demand such as food packaging plants and automated manufacturing systems although a large enough number of intermittent demands, along with some storage, will also present a suitably continuous load. In addition to fixed units, rotary-screw compressors are commonly mounted on tow-behind trailers and powered with small diesel engines. These portable compression systems are typically referred to as construction compressors. Construction compressors are used to provide compressed air to jack hammers, riveting tools, pneumatic pumps, sand blasting operations and industrial paint systems. They are commonly seen at construction sites and on duty with road repair crews throughout the world.Screw air compressors are also commonly used on Rotary, DTH and RC drill rigs used in mining production and exploration drilling applications and in oil and gas pipeline services such as pneumatic testing or air pigging.
Oil-free
In an oil-free compressor, the air is compressed entirely through the action of the screws, without the assistance of an oil seal. They usually have lower maximal discharge pressure capability as a result. However, multi-stage oil-free compressors, where the air is compressed by several sets of screws, can achieve pressures of over and output volume of over.Oil-free compressors are used in applications where entrained oil carry-over is not acceptable, such as medical research and semiconductor manufacturing. However, this does not preclude the need for filtration, as hydrocarbons and other contaminants ingested from the ambient air must also be removed prior to the point of use. Consequently, air treatment identical to that used for an oil-flooded screw compressor is frequently required to ensure quality compressed air.
Some small piston compressors use the term "oil free" to refer simply to the use of Teflon-type coatings on wear surfaces.
Oil-injected
In an oil-injected rotary-screw compressor, oil is injected into the compression cavities to aid sealing and provide cooling for the gas charge. The oil is separated from the discharge stream, cooled, filtered and recycled. The oil captures non-polar particulates from the incoming air, effectively reducing the particle loading of compressed-air particulate filtration. It is usual for some entrained compressor oil to carry into the compressed-gas stream downstream of the compressor. In many applications, this is rectified by coalescer/filter vessels. Refrigerated compressed air dryers with internal cold coalescing filters are rated to remove more oil and water than coalescing filters that are downstream of air dryers, because after the air is cooled and the moisture is removed, the cold air is used to pre-cool the hot entering air, which warms the exiting air. In other applications, this is rectified by the use of receiver tanks that reduce the local velocity of compressed air, allowing oil to condense, drop out of the air stream, and to be removed from the compressed-air system by condensate-management equipment.Oil flooded screw compressors are used in a wide variety of applications including air compression, gas refrigeration, hydrocarbon processing and power utilization from low-grade heat sources. Sizes range from small workshop air compressors to heavy industrial compressors with output pressures as high as. New oil flooded screw air compressors release <5 mg/m3 of oil carryover.