Atlas Copco Oil-Injected Rotary Screw Compressors are among the most popular and versatile types of air compressors used in various industrial applications. Known for their efficiency, reliability, and robust design, these compressors are engineered to provide continuous, high-quality compressed air with minimal maintenance requirements. They are particularly well-suited for industries where a consistent air supply is critical, such as manufacturing, automotive, construction, and food and beverage processing.
How Oil-Injected Rotary Screw Compressors Work
Oil-injected rotary screw compressors operate based on the principle of positive displacement. The key components are a pair of helical rotors (screws) that mesh together inside a chamber. Here’s how the process works:
Air Intake:
- Ambient air is drawn into the compressor through an intake valve. This valve regulates the amount of air entering the compression chamber based on the system's demand.
Compression Process:
- As the rotors spin, they trap the air between the screw threads and compress it as it moves along the length of the rotors. The volume of air decreases, causing its pressure to increase.
- During this process, oil is injected into the compression chamber. The oil serves multiple purposes: it lubricates the moving parts, helps to seal the space between the rotors, and absorbs the heat generated during compression.
Air-Oil Separation:
- After the compression process, the air-oil mixture passes into an air-oil separator tank, where the oil is removed from the compressed air. The oil is then filtered and cooled before being recirculated back into the compressor system.
Cooling and Filtration:
- The compressed air is cooled down using an aftercooler, reducing its temperature and removing moisture. The cooled, filtered air is then delivered to the air receiver or directly to the pneumatic tools and equipment.
Oil Recirculation:
- The separated oil is filtered to remove impurities, cooled, and then recirculated back into the compression chamber, making the process efficient and minimizing waste.
Key Features of Atlas Copco Oil-Injected Rotary Screw Compressors
High Efficiency:
- Atlas Copco’s rotary screw compressors are designed with energy efficiency in mind. The use of advanced rotor profiles and precision engineering reduces internal leakage and minimizes energy consumption during operation.
Variable Speed Drive (VSD) Technology:
- Many models come with Variable Speed Drive (VSD) technology, which adjusts the motor speed based on the air demand in real time. This capability can result in significant energy savings, often reducing energy consumption by up to 35% compared to fixed-speed compressors.
Integrated Air Treatment:
- These compressors often include integrated air dryers and filtration systems. This ensures the delivery of clean, dry air, which is essential for applications requiring high air quality and prevents issues like corrosion and contamination in the downstream equipment.
Low Noise Levels:
- Oil-injected rotary screw compressors are known for their quiet operation compared to reciprocating compressors. Atlas Copco models typically feature soundproofing measures and optimized cooling systems that reduce noise, making them suitable for installation in work environments where noise levels need to be controlled.
Advanced Control Systems:
- Atlas Copco incorporates advanced control systems such as the Elektronikon® controller. This system allows users to monitor and manage compressor performance, control parameters, and receive alerts for maintenance needs. The controller can be integrated with plant management systems for enhanced monitoring and optimization.
Durability and Reliability:
- The robust design and high-quality components of Atlas Copco compressors ensure a long service life. The use of durable materials, effective oil filtration, and efficient cooling systems minimizes wear and tear, resulting in reduced downtime and lower maintenance costs.
Advantages of Oil-Injected Rotary Screw Compressors
Continuous Operation:
- These compressors are capable of delivering a continuous supply of compressed air, making them ideal for applications that require 24/7 operation. They are less prone to overheating compared to other types of compressors, thanks to the cooling effect of the injected oil.
High Output and Efficiency:
- Oil-injected rotary screw compressors can achieve high compression ratios with excellent efficiency. They are designed to operate at high flow rates and pressure levels, providing a reliable air supply for demanding applications.
Long Service Intervals:
- The use of oil for lubrication, cooling, and sealing reduces wear on the internal components, extending the service life of the compressor. Regular maintenance intervals are typically spaced out, lowering overall operating costs.
Versatility:
- Atlas Copco’s oil-injected rotary screw compressors are available in a wide range of sizes and configurations, from small, portable units to large, stationary systems. This versatility allows them to be used in diverse applications, from workshops to large industrial plants.
Common Applications
Oil-injected rotary screw compressors are widely used across various industries due to their efficiency and reliability. Some common applications include:
- Manufacturing: Supplying compressed air for pneumatic tools, automation systems, and material handling.
- Automotive Industry: Powering paint spraying, assembly line tools, and tire inflation systems.
- Food and Beverage: Providing compressed air for packaging, bottling, and processing lines (where non-contact with food is required).
- Construction: Operating heavy-duty tools such as jackhammers, drills, and concrete pumps.
- Textile Industry: Driving air-jet looms and other air-powered machinery.
Maintenance and Service
Atlas Copco emphasizes the importance of regular maintenance to ensure optimal performance and longevity of their compressors. Key maintenance tasks include:
- Oil Changes: Regularly replacing the oil to maintain lubrication and cooling efficiency.
- Filter Replacement: Changing air, oil, and separator filters to prevent contamination and ensure clean airflow.
- Checking Belts and Seals: Inspecting and replacing worn belts and seals to maintain efficient operation and prevent leaks.
- Monitoring System Parameters: Using the built-in control system to track performance indicators such as temperature, pressure, and motor load.
Atlas Copco also offers comprehensive service packages, including remote monitoring, predictive maintenance, and tailored maintenance plans to help users maximize the uptime and efficiency of their compressors.
Conclusion
Atlas Copco’s oil-injected rotary screw compressors are known for their superior performance, energy efficiency, and reliability. With features like VSD technology, integrated air treatment, and advanced control systems, these compressors provide a versatile and robust solution for industries that require a dependable supply of compressed air. By combining cutting-edge technology with a focus on durability and maintenance ease, Atlas Copco continues to set the standard in the compressed air industry, making their oil-injected rotary screw compressors a preferred choice for a wide range of applications.
