Enhancing Efficiency in Screw Compressors Through Sustainable Polyglycol-Based Lubricants

Abstract This research examines the transformative impact of synthetic lubricants, particularly polyglycol-based oils, on the operational efficiency of screw compressors, emphasising the advancement of sustainable industrial practices. The synthetic oil, noted for its superior oxidation stability, prolongs oil change intervals and enhances the longevity of filters and separators. The integration of specialised inhibitors guarantees the preservation of internal compressor cleanliness, resulting in continued high efficiency. Experimental investigations comparing synthetic polyglycol oil to conventional mineral oil in screw compressors indicate substantial enhancements in overall efficiency. The synthetic oil offers extended maintenance intervals, achieving up to 8,000 operating hours in oil-injected screw-type compressors and 40,000 operating hours in turbocompressors, alongside prolonged filter and separator lifespans and diminished cleaning expenses due to its exceptional dirt-dissolving properties. Additionally, the synthetic oil aids in sustaining low oil vapour levels in compressed air, minimising oil use, and averting the gumming of pneumatic valves. The synthetic oil adheres to industrial requirements (DIN 51506-VDL and ISO 6743-3 L-DAJ) and demonstrates outstanding wear prevention for steel friction components. Possessing a kinematic viscosity of 55 mm $$^{2}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:mmultiscripts> <mml:mrow/> <mml:mrow/> <mml:mn>2</mml:mn> </mml:mmultiscripts> </mml:math> /sec at 40 $$^{\circ }$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:mmultiscripts> <mml:mrow/> <mml:mrow/> <mml:mo>∘</mml:mo> </mml:mmultiscripts> </mml:math> C, it exceeds bearing life specifications, hence forming an efficient lubricating coating for anti-friction bearings. The study highlights the considerable potential of sustainable lubricants, especially polyglycol-based oils, in improving efficiency and reinforcing the environmental sustainability of screw compressors. This study offers significant insights into the practical applications of synthetic lubricants in industrial settings, highlighting polyglycol-based oils as a viable solution for enhancing screw compressor technology. The study elucidates a vital element of sustainable materials within the industrial sector, providing an in-depth comprehension of their influence on machinery efficacy.