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December 4, 2024The Top 20 Benefits of Rotary Screw Compressors for Industrial Use
Kaishan USA | November 27, 2024| Uncategorized
Rotary screw compressors perform reliably and efficiently in a wide range of industries, including power generation.
Most industrial facilities use one of three main types of air compressors: reciprocating, centrifugal or rotary screw air compressors. Because of their reliability, efficiency and long life, rotary screw air compressors are the best industrial air compressors for most applications.
They flourish in industries as varied as general manufacturing, construction, oil and gas, food and beverage, life sciences, semiconductor fabrication, textile, power generation and automotive manufacturing.
They can even handle rugged conditions, such as those in the mining, oil and gas and metallurgy industries, providing a reliable, consistent fourth utility (joining electricity, gas and water) in challenging environments.
The best rotary screw air compressors can handle rugged conditions in applications like metallurgy.
Specific benefits of rotary screw air compressors include the following advantages:
1. Best Overall Efficiency with Variations in Demand
Rotary screw compressors deliver more compressed air per horsepower across varying demands, giving you more power and flexibility than other types of compressors. They have a simple, time-tested design that enables impressive efficiency.
2. Easy to Accommodate with VSDs
Almost tailor-made for variable-speed drive technology, rotary screw air compressors equipped with VSDs operate more efficiently at part loads. As a result, VSDs have enabled many companies to save significant amounts of energy and expense. But they are not for everyone. For more on the pros and cons of VSDs, see our blog post, “How Variable-Speed Drive Rotary Screw Air Compressors Save You Money.”
3. Two-Stage Compressors
By dividing the compression cycle into two steps, a two-stage model such as Kaishan’s KRSP2 premium rotary screw air compressor will generate up to 15-20% more flow in the same size air compressor, a payback that will recoup the price difference quickly.
Kaishan’s KRSP2 two-stage rotary screw air compressors are some of the most energy-efficient machines on the market.
4. Heat Recovery
Rotary screw air compressors can be equipped with systems to recover heat that is ultimately used in applications such as water heating, drying or warming food. In northern climates, you can even do space heating.
According to Compressed Air Best Practices, you can recover up to 90% of the heat removed from your compressed air system. And Manufacturing.net places the figure as high as 96%.
For more information on configuring your compressed air system to maximize heat recovery, see our blog post, “Compressor Room Design.”
5. Safety
Unlike other compressor manufacturers, we display the power consumption on your compressor’s control screen, primarily as a safety issue. We believe that you shouldn’t have to stop production or put people in harm’s way to get that data. So, we put it at your fingertips.
We display your compressor’s power consumption prominently to help your people diagnose your machines safely.
6. Steady Air Flow
Rotary screw air compressors do not produce the pulsations that sometimes occur with other types of compressors, especially reciprocating or piston compressors. They are known for generating steady streams of compressed air.
7. Versatile
Rotary screw compressors can handle changes in demand better than most other types of compressors. When properly prepared, they can withstand extreme weather conditions and rugged industrial environments. You should, however, adjust service intervals to allow for dirty and dusty conditions.
8. Less Maintenance
Rotary screw air compressors have relatively few moving parts and, as a result, are less costly to maintain. They occasionally require the skills of advanced maintenance professionals. In addition, Kaishan compressors are designed to allow easy access to all major components.
9. Reliable
Rotary screw air compressors are based on a simple, time-tested design with relatively few moving parts, so they are highly reliable and cause less unexpected downtime.
They are durable and long-lasting, and many continue to operate efficiently for years if not decades. Plus, they are well-equipped to handle variations in demand and changing temperatures.
10. Small Footprint
They have a compact footprint, occupying less floor space than other types of compressors.
11. Less Vibration, Quieter
Rotary screw air compressors create less vibration and noise and are much quieter than other compressors. Kaishan customers who specifically called out the lower sound levels of our machines included Factory Finish Smart Repair, Hubbard Feeds, Strategic Materials and Custom Thermoelectric.
12. Great Warranties
Because of their reliability and long life, rotary screw compressors have better warranties than other compressor models. In fact, Kaishan backs its KRSP and KRSP2 rotary screw compressors with a lifetime warranty on the airend.
We back our KRSP and KRSP2 rotary screw compressors with an unmatched lifetime airend warranty.
13. Fast-Reacting
Rotary screw compressors respond quickly to changing demands, unlike other compressors that take time to ramp up pressure and flow.
14. Robust
Rotary screw air compressors work best with a 100% duty cycle. In fact, we recommend that you operate them as close as possible to full load. Reciprocating compressors, by comparison, need time to cool down and can only operate 30 minutes in an hour.
15. Easy to Link Multiple Units Together
16. Easier to Do Higher Pressures
Rotary screw compressors are better than other compressor types at meeting the needs of end-use applications that require high horsepower levels (up to 600 HP).
Applications such as electronics, food and beverage, healthcare and medical devices need high-quality, oil-free compressed air.
17. Clean Air
Rotary screw air compressors provide a steady flow of high-quality air, free of impurities. They minimize the pulsations that sometimes occur with other types of compressors, especially reciprocating machines.
If you need oil-free compressed air for applications such as food and beverage, electronics, healthcare and medical devices, you now have a new alternative offering some compelling new advantages in reliability, efficiency and warranty protection.
Our new KROF oil-free rotary screw compressor, produces ISO 8573-1, Class 0 oil-free compressed air that safeguards the integrity of your products. It is available in 100-, 125- and 150-PSIG models with integrated air or water cooling.
Our KROF oil-free rotary screw compressor, produces oil-free compressed air suitable for applications needing high-quality air.
18. Easy Installation
Because they have a low vibration, rotary screw air compressors do not need to be bolted down. They need a level slab that can accommodate the weight of the machine.
19. Lower Lifetime Costs
Because of their rugged reliability, energy efficiency, extended lifetime and warranty protection, rotary screw air compressors have lower lifetime costs and total cost of ownership than other compressor types.
20. Readily Available
Kaishan maintains a large inventory of machines for quick delivery, while other manufacturers often quote long lead times, which often add costs, including the need to rent a compressor.
We also work with a nationwide network of independent distributors, who can offer on-site help and consultation as needed and can even service your air compressor system. They have staff members who are skilled in using advanced technology to help you maintain and optimize the performance of your compressed air systems.
Key Takeaways
The best rotary screw air compressors provide several critical benefits for the typical industrial facility, including:
- Performance: The best rotary screw air compressors enable you to run equipment and tools with high horsepower requirements. They deliver impressive efficiency and can handle a 100% duty cycle, providing a steady flow of clean, high-quality air.
- Operational: Because they have fewer moving parts, the best rotary screw air compressors are highly reliable and require less maintenance. They can handle variations in demand and temperature extremes and are relatively safe. They have a compact footprint and generate less noise.
- Cost: The best rotary screw air compressors operate reliably and dependably, which means that you will have less downtime. They have a longer lifespan and a relatively low total cost of ownership. Plus, they have better warranties than other types of air compressors because of their reliability, efficiency and long life.
Let Us Help
Selecting the best industrial air compressor for your operation is critical to the success of your compressed air system and all the processes that rely on that system. If you need help deciding which type or model of compressor is right for you, get in touch with the experts at Kaishan. Contact us today.
