There are some environments where air purity is critical, and any oil contamination within the air can cause the final product to spoil or damage the production equipment in use. Usually specified with safety in mind, oil-free compressors offer a safe solution for either manufacturing personnel or the end user where air purity is critical. We take a look at oil-lubricated air compressors vs. oil-free to see how they each stack up.
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Oil-free air compressors have been developed for use in applications where oil within the compressed air would be unacceptable. An oil-free compressor is not completely free of oil. However, there is no oil in the compression chamber and the components that require oil for lubrication, such as bearings and gears, are isolated from the compression chamber itself. This keeps the resultant compressed air 100% free of oil contaminants.
Whereas an oil-lubricated compressor would usually use oil for cooling purposes, in a rotary screw oil-free compressor there is usually an air cooler after each stage of the process. Some oil-free compressors use injected water to remove the heat created by the compression process.
An oil-lubricated compressor uses oil for lubrication and cooling, which helps to reduce friction, dissipate heat, and enhance efficiency by injecting oil into the compression process. The oil is then separated from the compressed air to provide clean, high-quality air. These compressors are commonly used in industrial and manufacturing settings due to their reliability and long-term use.
To ensure an oil-lubricated compressor never contaminates the compressed air, proper and regular air compressor maintenance must be done.
As with all things, there is never just one solution to fit every scenario perfectly. Oil-free compressors have distinct advantages in some environments but are not necessarily the best solution for every business or application. We&#;ve looked at the advantages and disadvantages of both oil-free compressors and oil-lubricated compressors to help provide context.
Non-contaminated air: Given that this is the key reason for their existence, this must be included. Industries such as food processing, electronics and pharmaceuticals are common users of the oil-free compressor. Filters can be used as a solution to creating oil-free air, but most processing businesses that need oil-free compressed air choose to go with oil-free compressors.
Low-cost: Because they&#;re simpler in design than oil-lubricated compressors and with fewer parts, oil-free compressors are, generally, less expensive to produce.
Lower maintenance demand: As there are fewer moving parts and less oil to change, there is a lower chance of problems arising, and needing to be fixed, as well as less time to be dedicated to servicing and maintenance.
Limited durability: Oil-free compressors generally have a shorter lifespan compared to oil-lubricated systems because they experience more wear and tear because of the lack of lubrication.
Higher operating temperatures: Oil-free compressors often run at higher temperatures which can impact efficiency and potentially lead to overheating issues.
Expensive maintenance: While oil-free compressors are, generally, lower in cost, their maintenance costs may be higher because they require more frequent replacement of components.
Longer life span: Oil-lubricated compressors are more durable and are well suited to industrial environments and long working hours. In comparison, many oil-free compressors can only cope with low usage levels and will need to be replaced more often.
Lower noise levels: The lubrication in oil compressors means that they produce far less noise than their oil-free counterparts, which is often a point of concern in industrial manufacturing environments.
Less heat production: The oil helps to remove heat from the process of compression in oil-lubricated compressors. This means that they produce less heat during operation and help to maintain a more consistent processing environment.
Oil contamination: Oil-lubricated compressors can, occasionally, introduce oil contaminants into the compressed air, which may not be suitable for certain applications.
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Maintenance complexity: These compressors require regular oil changes and oil filter maintenance which makes them more complex to maintain compared to oil-free compressors.
Environmental impact: The disposal of used compressor oil can be an environmental concern if it&#;s not handled properly. It requires proper disposal methods to prevent damage to the environment.
It is clear, then, that when it comes to the question of oil-lubricated air compressors vs. oil-free compressors, there is not a straightforward answer that suits every situation. The application is the most critical factor in terms of safety and hygiene for those who opt for an oil-free compressor solution, but where lifespan and operating conditions are paramount, it may be that the oil-lubricated air compressor makes more economic sense overall and is more suited to the industrial application in question.
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I work with and on many types of air compressors. Years ago, the medical field, scuba diving, and air exchange like mine shafts and sewer systems would be the only oil-free compressors to be found. Oil-free became oil-less Air Compressors and started popping up for home use. The advantage mainly was fewer parts and more compact resulting in a lower affordable cost. Unfortunately, they were garbage! Homeowners may get a few years of use from an oil-less compressor but avoid using it because it was so loud. Professionals hated them. They didn&#;t last, It would shake across the floor, and the noise was unbearable.
Flash forward to today&#;s quiet direct drive motor two-stage oil-less air compressor, and it is my goto on the go. Most of the tools I have, including an air impact, can be run from a small compressor for a short period. The lightweight all-in-one carrying frame is mobile.
Holding a conversation with it running next to you is not a problem, even with my hearing.
I have a single-stage oil-lubricated compressor at home. The added initial cost will pay off with trouble-free reliability, With an oil-less compressor, the cost would be approximately 20% less, and the decibels would be too loud to store it in my attached garage.
What are some pros and cons of oil-free air compressors?
Both types of compressors function much like your car&#;s engine,
Only without a spark plug and an exhaust stroke. The piston is pulled down, drawing in the fresh air, then is driven up, increasing the pressure. The main difference is the oil-less compressor uses permanently sealed bearings and synthetic gel lubricants.
The oil-less system doesn&#;t have an oil reservoir Eliminating oils from passing the pistons&#; rings and into the compressed air system.
To answer this question, let us take a look at a comparison between two compressors on the market manufactured by the same company. Here you see a chart with a side-by-side comparison.
Please take note that the side-by-side comparison is not answering the question entirely.
oil- free compressor oil lubricatedWarranty2 years2 yearstank size27 Gal30Galdecibels(out side)80Db78Dbmax pressure 200 psi175 psihorse power1.7hp2.0 hpcfm @ 40psi5.1 cfm6.2 cfmcfm @ 90psi6.8 cfm7.7 cfmamp ratingweightcost at time of articleAt first glance of these two similar performing compressors the one hundred dollar cost of the oil lubricated compressor sticks out, the oil-less is only 2 decibels louder, one-half CFM, at 90 psi less than the competitor and lacks only point three horse power.
The biggest concern I have About larger oil-less compressors is Duty-Cycle, I have not seen Duty cycle ratings on any paperwork or online in quite some time. &#;Duty-cycle&#; is the amount of time the compressor needs to rest and cool compared to the amount of time it runs. an example of this is a 100% duty cycle rated compressor that will not need to shut off to cool it can stay cool and run non-stop, A 75% duty-cycle rated compressor can run for 45 minutes but then needs to cool off for 15 minutes before restarting. in the case of these two compressors, the oil-less has to work much harder when it turns on at 95 psi to get back to 200 psi. both compressors hold about the same volume of air. but the oil-lubricated compressor only has to reach 175 psi, which will equate to shorter run times and a longer life span.
We&#;ve talked about all of the benefits. Oil-less air compressors are cheaper than their oil-using counterparts. Because the oil-less compressor is smaller and lighter, it is more cost-effective to manufacture. The energy costs are also reduced because there is no need to collect and store oil-laden condensate. both types of compressors have their place, and I own both
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