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Can two stage compressors save an operator money?

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article image KHE two-stage screw compressor

Southern Cross Compressors Australia Pty Ltd states that two-stage compression can save thousands of dollars in energy and maintenance costs for the operator.

Companies requiring a rotary screw compressor of 90kW or above should consider the benefits of a two-stage compressor over a typical single stage machine. Single-stage compressors use one air end to compress air to the required system pressure whereas a two-stage compressor separates the compression process over two separate air ends. 

A two-stage screw compressor can provide total efficiency savings of 15-20% over a single-stage equivalent screw compressor, resulting in faster payback on the additional capital investment. Two-stage compressors can be combined with Variable Speed Drives (VSD) to get high efficiency over the full demand range.

A two-stage screw compressor works by splitting the compression process between two air ends resulting in better efficiency due to a lower compression ratio in each air end. Lower compression ratios result in reduced internal losses compared to a single-stage air end.

After compression in the first stage air end, the air is intercooled to reduce the temperature, which decreases the amount of work required for the second stage air end to achieve the set operating pressure, further boosting efficiency and reducing energy consumption.

The shared compression load results in less axial load on the air end bearings, extending bearing life and lowering maintenance costs over the life of the compressor.

Southern Cross Compressors Australia Pty Ltd can be contacted for more information on the benefits of two-stage screw compressors or the industry leading range of KHE two-stage compressors. 

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