The oil-injected screw air compressor realizes sealing and cooling by injecting lubricating oil into the compression chamber, and the oil content of the outlet air is the core index to measure the performance and air quality of the equipment. The following four aspects of oil content standards, influencing factors, control technology and industry applications are discussed to provide reference for enterprises to optimize compressed air systems.
Oil Content Standard and Industry Requirements for 1. Export
- general Standard Scope
- the oil content at the outlet of the oil-injected screw air compressor is usually3-5mg/ m³the specific value depends on the model design, filtration system configuration and operating conditions.
- Example: The oil content of a certain type of screw machine can be stably controlled within 3 mg/m under rated working conditions.
- Industry differences in demand
- general industry: Allowable oil content ≤ 5mg/ m³ suitable for machining, pneumatic tools and other scenarios.
- Precision Manufacturing: oil content ≤ 1mg/ m³, such as electronic component assembly, food and pharmaceutical packaging.
- Special process: oil content ≤ 0.01mg/ m³, such as semiconductor etching, optical fiber production.
Key influencing factors of 2. oil content
- equipment ontology factor
- screw accuracymachining errors such as rotor meshing clearance and bearing clearance directly affect the amount of oil carried.
- Oil system efficiency: Oil and gas separation tank design, filter material and filtration accuracy determine the oil removal rate.
- Influence of operating conditions
- load fluctuationduring low load operation, the temperature drop in the compression chamber causes the lubricating oil to emulsify, increasing the risk of oil discharge.
- Ambient temperature: High temperature environment reduces the viscosity of lubricating oil and aggravates the volatilization of oil.
- Maintenance management factors
- filter element replacement cycle: After the filter element is blocked, the pressure difference increases, causing the oil to penetrate.
- Oil selection: The use of inferior lubricating oil is easy to produce carbon deposits and block the oil filter element.
Core Technology of 3. Oil Content Control
- optimization of Oil and Gas Separation System
- multi-stage separation design: Using centrifugal separation fiber filtration fine filtration three-stage separation technology, the oil removal rate can reach 99. 99%.
- Filter element material upgrade: Using borosilicate fiber filter material, the filtration accuracy is improved to 0. 1μm.
- intelligent control system
- frequency conversion regulation: Automatically adjust the speed according to the air consumption to avoid low-load oil discharge.
- Oil temperature managementconfigure thermostatic valve and electric heater to ensure that the oil temperature is stable at the best separation interval of 70-85 ℃.
- Maintenance Specification
- filter element replacement cycle: It is recommended to replace the oil filter element every 2000 hours and the oil filter every 4000 hours.
- Oil detectionregularly detect the viscosity, acid value and moisture content of lubricating oil, and replace the deteriorated oil in time.
Oil Content Control Scheme for 4. Different Scenes
| application Scenarios | oil content target | technical configuration |
|---|---|---|
| general Machining | ≤ 5mg/ m³ | standard three-stage oil and gas separation regular filter element replacement |
| Precision Electronics Manufacturing | ≤ 1mg/ m³ | enhanced fine filtration system (filtration accuracy 0. 01μm 2) Activated carbon adsorption unit |
| food and medicine packaging | ≤0.1mg/ m³ | stainless steel pipe sterile filtration system online oil detector |
| semiconductor Production | ≤0.01mg/ m³ | catalytic oxidation degreasing unit molecular sieve dryer HEPA filtration system |
5. oil content abnormal processing flow
- online monitoring
- install laser particle counter or infrared oil detector to monitor oil content in real time.
- fault diagnosis
- when the oil content exceeds the standard, check according to the sequence of “filter element blockage → oil deterioration → separator failure.
- Emergency measures
- temporarily activate the standby air compressor and cut off the air supply of the faulty air compressor.
- After replacing the filter element or adding lubricating oil, restart the equipment and observe the change of oil content.
Conclusion
the oil content at the outlet of the oil-injected screw air compressor needs to be comprehensively controlled in combination with industry standards and gas usage scenarios. By optimizing the separation system, intelligent operation management and fine maintenance, the compressed air quality can be significantly improved. Enterprises should establish an oil content monitoring system and regularly evaluate the performance of the system to ensure that the outlet air of the air compressor meets the production process requirements, while reducing the risk of lubricating oil consumption and environmental pollution.
