Atlas Copco Oil-Injected Air Compressors - The Compressed Air Blog

Imagine you are driving your car on a hot day. Your dashboard indicates you are low on oil and need an oil change. Your engine is running hot. You change the oil, which gets filtered through your car engine and cools the vehicle down. The car runs smoother because the oil is lubricating the engine and making everything run more efficiently and reliably.

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Now think of a rectangular air compressor device, about six feet high and five feet wide, inside a furniture manufacturing facility. Using oil to lubricate the air compressor motor within that facility will make the manufacturing process run efficiently and smoothly. The air, which gets hot when compressed, won’t overheat because the oil will keep it cool. The compressor will function well because the oil will keep the engine lubricated and running efficiently so the furniture-making process progresses accurately and efficiently while minimizing energy consumption and accelerates the manufacturing environment. 

This is an example of an oil-injected air compressor application! These machines are absolutely essential in powering a large variety of applications and industries - many of which wouldn't function without oil-injected compressors.

In more technical terms, oil-injected air compressors (also known as oil-flooded or oil-lubricated compressors), are compressors that use oil to lubricate the air compression chamber, lubricate parts, and seal in the air. In this device, a liquid is injected into the compression chamber and often into the compressor bearings. Its function is to cool and lubricate the compressor element's moving parts and the air being compressed internally. The compressor also reduces return leakage to the inlet. Oil is the most commonly injected liquid due to its effective lubricating and sealing properties. If the oil gets too hot, the substance gets funneled to a cooler within the compressor.

Air purity is critical for many applications where even the tiniest drop of oil, or air contaminated with oil can cause product spoilage, product recall or damage production equipment. Your specific application will determine which type of air compressor is best for you to use in your facility.

In instances where the threat & consequences of oil contamination are too high, like medical procedures, having an oil-free air compressor is a must. In applications where the consequences of oil contamination are not as great, such as general manufacturing & in industrial and small workshops, oil-injected air compressors are used.

Key takeaway: Oil-free air compressors are not necessarily “better” than oil-lubricated compressors. The compressor you choose depends on your specific application requirements and the air quality that you need to achieve!

In the world of air compressors, choosing between oil-free and oil-lubricated models can be confusing and daunting.

Both types have unique benefits and limitations, and making the right choice depends on your industry or specific application needs and requirements.

This blog will help you understand the critical differences between oil-free and oil-injected air compressors and provide you with the information you need to make an informed decision.

Whether you're a professional mechanic or a manufacturing plant manager, this article will give you a better understanding of the pros and cons of each type and help you determine which one is right for your industry application.

What Is an Oil Free Scroll Compressor?

A scroll compressor is also referred to as a spiral compressor, a scroll pump or a scroll vacuum pump. The rotary spiral scroll design creates a continual compressed air flow over multiple stages and there is no need for oil lubrication.

Does That Mean That Oil-Free Has No Oil At All?

Oil-free air compressors do not contain oil in their element or anywhere in the path of the process air being compressed. However, they still use oil for the bearings and gear in the mechanical drive system to ensure smooth operation.

The gearbox is a crucial component of the air compressor, driving the compressor elements with the help of a drive motor. Regular maintenance checks are essential to keep the gearbox lubricated and functioning smoothly, as replacing these components can be costly. The oil in the gearbox lubricates the internal gears, bearings, and other parts. It is cooled and filtered before being re-circulated, ensuring efficient cooling of the elements and gearbox parts.

Despite the presence of oil in the mechanical system, the oil is entirely absent in the compressed air circuit. This separation guarantees the highest air quality for your application. It also simplifies day-to-day maintenance activities by reducing service interventions and improving efficiency by avoiding unnecessary pressure drops in the line filters.

Oil-Free vs. Oil-Injected Air Compressors: Major Differences

The Presence of Oil

Oil-free air compressors do not have any oil mixed in the compression chamber. They rely on Teflon-coated screw elements and two-stage compression (using two elements) to generate compressed air without compromising air quality.

In contrast, oil-injected air compressors use oil to lubricate the moving parts and ensure smooth operation. The oil also helps to cool the element, acts as a sealant, and removes contaminants from the air stream.

As its name suggests, an oil air compressor requires oil to lubricate its moving parts. For instance, in a rotary screw air compressor with lubricated helical screw pairings, regular oil and oil filter changes are necessary to maintain proper operation. In contrast, oil-free air compressors utilize alternative lubrication methods, eliminating the requirement for oil altogether.

Maintenance

Maintenance is a significant factor when choosing the type of air compressor. Oil-free compressors generally require less maintenance, as there is no need to change large quantities of oil or separators, oil filters etc. In contrast, oil-lubricated compressors require more maintenance, including frequent oil changes and cleaning of the lubrication system.

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Comparatively, oil-free scroil air compressors come with fewer maintenance needs, but they tend to not last as long as a properly maintained lubricated system. Once the frictionless coating starts wearing off in oil-free compressors, you will need to replace your compressor in short order. They also run hotter than lubricated systems.

Application

Oil-lubricated compressors are typically used in industries where air quality is not a primary concern, such as cement, metal, plastic, or general manufacturing. In contrast, oil-free compressors are better suited for applications where clean, oil-free air is essential.

Oil-Free Vs. Oil Air Compressors: What Are The Suitable Industries?

Industries using oil-free air compressors:

Food and beverage industry

Pharmaceutical industry

Electronics manufacturing

Chemical and petrochemical industry

Fertilizer manufacturing

Aerospace and defense

Industries using oil-lubricated air compressors:

Automotive repair shops

Construction sites

General manufacturing

Mining indusry

Oil and gas industry

Oil-Free Vs. Oil-Injected Air Compressors: Which One Is Right for You?

Choosing between oil-free and oil-lubricated air compressors can be difficult, as both types have unique benefits and drawbacks. When deciding which one is right for you, it's essential to consider several factors, including the specific needs of your application, the type of work you will be performing, and your budget.

An oil-free compressor may be the best choice for applications where clean, oil-free air is a top priority, such as in the food and beverage industry, pharmaceuticals, and electronics manufacturing. In addition to Class 0 air quality benefits, oil-free compressors are also chosen for lower maintenance and operating energy costs, as well as reduced environmental impact.

On the other hand, an oil-lubricated compressor may be more suitable for general manufacturing where initial cost is a primary consideration in the selection process.

Conclusion