Risks of Prolonged Low-Load Operation in Screw Air Compressors

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Risks of Prolonged Low-Load Operation in Screw Air Compressors

Release time:

2025-07-08

1. Oil Contamination and Component Degradation
Operating a screw air compressor at low load over an extended period can lead to poor oil circulation, resulting in the accumulation of oil sludge inside the system. This buildup adheres to internal components, increasing resistance and reducing overall efficiency. Moreover, components that come into direct contact with lubricating oil—such as rotors, bearings, and seals—are particularly vulnerable to accelerated aging and wear. Over time, this degradation significantly raises the risk of mechanical failure.

2. Increased Energy Consumption and Operational Costs
When a screw compressor runs under light load or in unloaded conditions, energy consumption may rise by 30–40% compared to normal operation. This is because key components like rotors and bearings continue to operate and consume energy even when the machine isn’t delivering optimal output. This inefficiency results in higher electricity bills and unnecessary waste of power—an especially critical issue today as energy conservation becomes central to sustainable business practices.

3. Lubricant Degradation and Risk of Major Failure
Lubricating oil plays a vital role in cooling and protecting internal components. However, during prolonged low-load operation, the oil temperature often fails to reach the optimal 80°C threshold. This can cause the oil to emulsify and degrade due to high moisture content and insufficient thermal conditions. As a result, the oil loses its lubricating properties, increasing the risk of rotor corrosion, seizing, or even complete failure of the airend. This issue is particularly severe in newer machines, where moisture accumulation in the compressor head can quickly lead to rust and damage.