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Screw compressors are essential elements in various industrial sectors, such as manufacturing, energy, and construction, representing roughly 10%–20% of industrial electricity usage. Notwithstanding their prevalent application, the energy requirements of multi-stage screw compressors substantially contribute to carbon emissions. The global market for screw compressors is anticipated to expand at a compound yearly growth rate (CAGR) of 6. 5%, achieving a market value of 19. 37 billion by 2030. This highlights the increasing demand for more energy-efficient compressor systems. The utilisation of multi-stage screw compressors for applications surpassing 30 bar is constrained by issues including rotor bending deformation, diminished bearing longevity, inadequate oil cooling, and condensate separation in oil separators. Moreover, screw compressors encounter operational constraints in multi-staging, even at reduced pressure ranges, when compared to reciprocating compressors. This study seeks to examine the existing constraints of multi-stage screw compressors and investigates potential solutions for power levels of 22–315 kW and delivery pressures of 6–12 bar. A cost-effective compressor design was designed by utilising modern rotor profiles and optimising sealing and cooling systems. A prototype two-stage oil-flooded air screw compressor, intended for water-well applications, was fabricated and evaluated for performance and dependability. The efficacy of the two-stage compressor was evaluated against that of a single-stage air screw compressor of comparable capacity. An extensive economic evaluation, grounded in lifecycle costs, was performed over a decade. The results indicate that the two-stage compressor reduces operational expenses by roughly 20%–75%, leading to markedly lower lifecycle costs. These insights underscore the capability of multi-stage screw compressors to provide improved performance and economic advantages, promoting broader implementation in applications necessitating mid-range pressures.
Kumar et al. (Sun,) studied this question.