In order to understand the differences between the rotary and reciprocating compressor, let’s first take a look at how each of these compressors work. While both reciprocating and rotary compressor use a positive displacement mechanism, rotary screw compressor has two rotors that compress the air as it moves through the compressor and reciprocating air compressor uses a piston to compress air and store it in a tank.
Learning the difference between rotary and reciprocating compressor is important because they each have different sets of characteristics and are better suited for different applications across various industries.
In our rotary compressor vs reciprocating compressor guide, we’ll focus on the differences between the two. For example, rotary screw compressors are generally more efficient and better suited for continuous duty applications, while reciprocating compressors are better suited for intermittent duty and lower flow rate applications. When you understand these differences, you’ll be better equipped to choose the right type of air compressor for your specific needs, which can result in better performance and cost savings.
A] The Major Differences Between Rotary Screw And Reciprocating Compressor
1. Flow Rate
Rotary screw compressors offer high flow rates, while reciprocating air compressors provide low flow rates suitable for precise control over air pressure and volume, commonly used in small-scale manufacturing, Plastic Molding, metalworking, batching plants and laboratory/medical equipments. Rotary screw compressors, with their high-flow rate, are used across industries that require large amounts of compressed air, such as manufacturing, construction, mining, textiles, food processing, and aerospace.
2. Compressor Speed
Rotary screw compressors provide a high-speed, efficient, and continuous supply of compressed air, making them ideal for heavy-duty industrial applications. Reciprocating air compressors, with lower speeds and precise control, is suitable for Service Stations, clothing and shoes, print and paper and shipping industry. Reciprocating compressors are known for providing precise control over air pressure and volume, making them ideal for applications that require high accuracy and control.
3. Maintenance
Rotary screw compressor requires low lubrication and maintenance compared to reciprocating air compressor. If a business requires an air compressor with low maintenance and lubrication requirements, a rotary screw compressor may be a better option. A screw compressor can help reduce downtime and maintenance costs. By doing so, it can increase overall efficiency and productivity. When businesses are equipped with such information, they can better plan their budget for maintenance and repair.
4. Air Delivery
Rotary screw compressors provide continuous delivery of air, while reciprocating compressors only supply intermittent air delivery. This makes rotary screw compressors ideal for applications that specifically require a constant and high volume of compressed air. Reciprocating compressors, on the other hand, are better for applications that need precise control over air pressure and volume.
5. Pressure Ratio And Delivery Pressure
Rotary compressors are ideal for applications that require lower pressure ratios and delivery pressure, while reciprocating compressors are more suitable for applications that require higher pressure ratios. This is why rotary compressors are used in various industries, such as manufacturing, construction, mining, food and beverage processing, textile manufacturing, chemical processing, steel plants, pharmaceutical industry and water treatment. Alternatively, reciprocating compressors with high-pressure ratios are used in applications such as pneumatic tools, vehicles’ air brakes, engine starting for ships, high-pressure air for filling cylinders and pet bottles and laser cutting.
6. Electricity Power Saving
Since rotary screw compressors consume less power, they are considered to be more efficient compared to reciprocating air compressors. This is because screw air compressors operate continuously and produce a steady flow of compressed air without the need for frequent start-stop cycles, which can result in energy wastage. Additionally, rotary screw compressors have fewer moving parts, which ensures there is less friction and lower energy consumption during air compression.
Reciprocating air compressors, on the other hand, require more power to operate, especially because of their intermittent delivery of compressed air, which requires frequent start-stop cycles. These compressors also have more moving parts, which can lead to greater friction and energy loss. However, there’s one thing to note, newer and advanced reciprocating compressors with cutting-edge technologies such as variable speed drives (VSDs) and improved design have shown significant improvements in energy efficiency.
7. Installation Space
Since rotary screw compressors have a compact design and are often integrated into a single unit with a filtration system, they require less installation space and footprint as compared to reciprocating air compressors. Reciprocating compressors, on the other hand, may require separate components, such as a receiver tank and additional filters. However, the actual space required may vary depending on the specific model and application requirements.
8. Free Air Discharge Rate
Rotary screw compressors operate continuously and produce a steady flow of compressed air, allowing for a higher volume of air to be compressed and discharged. Screw compressors gives 25% higher flow rates of air than reciprocating compressors. Reciprocating compressors, on the other hand, have an intermittent delivery of compressed air, resulting in a lower free air discharge rate. Regardless, you should keep one thing in mind, the exact free air discharge rate of both compressors will depend on factors such as their size, power, and operating conditions.
9. Places Used (Applications Across Industries)
Rotary screw compressors are widely used in various industries that require a reliable and efficient source of compressed air, such as Any Manufacturing, Construction, Mining, HVAC systems, Food and Beverage processing, Aerospace, Chemical processing, Pharmaceutical manufacturing, Packaging industry, Stationery, Polymers, Cable Manufacturing, Steel Industry, Engineering industry and Plastic Industry. They are also used in Textile manufacturing, Printing, Energy production, Waste treatment, and Water management industries and many more.
Reciprocating air compressors are used in industrial applications that require precise control over air pressure and volume, including Small-scale Manufacturing, Metalworking, Laboratory and Medical equipment, Dental equipment, Food and Beverage packaging, Paint spraying, Auto repair, Sandblasting, Printing and Paper manufacturing, Pet Bottle Manufacturing, Logistics Industry, Shipping Industry, Paper Industry Pharmaceutical manufacturing, Chemical processing, Aerospace and Aviation (for small-scale applications), and Electronics manufacturing and many more.
B] How to Choose the Right Type of Industrial Compressor: Rotary Screw Vs Reciprocating Air Compressors
1. Required Airflow And Pressure
While choosing the right air compressor, you need to consider the required airflow and pressure. Businesses and applications that require a large volume of air at lower pressures should consider investing in a rotary compressor as it would be more suitable. In contrast, if your requirements include the need for a smaller volume of air at higher pressures, then a reciprocating compressor would be more appropriate.2. Budget And Maintenance Costs
With respect to the budget and maintenance costs, rotary screw compressors may be a better choice as they generally have a longer lifespan and require less maintenance. However, let’s not forget that they can be more expensive upfront. In comparison, reciprocating compressors have lower upfront costs, but their maintenance and repair costs can add up over time. So, the decision depends on the specific needs and budget of the business or industry.3. Noise Level And Space Limitations
The noise level and space limitations are important factors to consider when choosing between screw compressors and reciprocating compressors. Rotary compressors are generally quieter and more compact than reciprocating compressors, making them ideal for indoor environments with limited space. However, if you factor in the noise levels and it is a major concern then you would be better off with a reciprocating compressor with a noise-reducing enclosure.4. Application-Specific Requirements
Ultimately, the final decision while choosing the right compressor depends on the specific application requirements of the business or industry. For instance, if the application requires a constant and high volume of compressed air, then a rotary compressor may be more suitable. On the other hand, if the application requires precise control over air pressure and volume, then a reciprocating compressor may be a better option. There are other factors one should consider while picking a reciprocating compressor, our guide, Tips for Choosing the Best Piston Compressor, can help you better find the right reciprocating compressor for your needs. It is, therefore, important to consider the applications-specific requirements to determine the most appropriate compressor between reciprocating and rotary compressor.Conclusion
In this screw compressor vs reciprocating compressor guide, we focused on their major differences including, flow rate, compressor speed, maintenance, air delivery, pressure ratio, delivery pressure, electricity power saving, installation space required, discharge rate, and applications across various industries. It is necessary to know all these factors to choose the right compressor that fits your requirements, especially between rotary and reciprocating compressors.
To quickly summarize, rotary screw compressors are typically more efficient, have a higher free air discharge rate, and require less installation space. Reciprocating compressors, on the other hand, are better suited for applications requiring higher pressure ratios and offer more flexibility in terms of airflow and pressure.
By learning and recognizing their differences and weighing the pros and cons, businesses and industries can select the appropriate compressor to meet their specific needs and optimize their operations.
If you are looking for either rotary screw air compressors or reciprocating air compressors in India, you should explore bimpex’s large collection of compressors.
If you are looking to purchase other types of air compressors, then you can refer to our guide: Everything You Should Know Before Buying An Air Compressor.
You can also get in touch with us and we’ll help you find the right air compressor that meets your business requirements.