Causes of carbon deposit on screw air compressor
DateTime：2025-08-24Source：u-air chainHits：
Carbon deposit is a common yet damaging issue in screw air compressors, threatening equipment lifespan, air quality, and operational safety—especially critical in sectors like pharmaceuticals where compressed air purity is non-negotiable. Understanding its root causes is key to prevention.
The primary culprit is lubricant degradation. Low-quality or mismatched lubricating oil, designed for general industrial use rather than high-temperature compressor environments, breaks down under heat (often 80-120℃ in compression chambers). This produces varnish-like residues that gradually harden into carbon deposits. Even quality oils degrade prematurely if overused beyond their recommended service life (typically 2,000-4,000 operating hours).
Abnormal operating temperatures exacerbate the problem. Clogged coolers (from dust or oil sludge) or malfunctioning temperature control valves fail to dissipate heat, pushing compression chamber temperatures above safe limits. Excessive heat accelerates oil oxidation, turning lubricants into carbonaceous deposits on rotors, valves, and exhaust systems.
Inadequate air filtration also contributes. Poorly maintained air intake filters allow dust, dirt, and debris to enter the compression chamber. These contaminants mix with degraded oil, forming abrasive sludge that adheres to surfaces and hardens into carbon. For pharmaceutical facilities, this not only damages equipment but also risks contaminating compressed air with particulate matter.
Improper maintenance practices compound risks. Infrequent oil changes, neglecting filter replacements, or using incompatible oil additives disrupt the lubrication system’s balance. Additionally, operating compressors at partial loads for extended periods (common in batch production) leads to incomplete combustion-like oil degradation, fostering carbon buildup.
Left unaddressed, carbon deposits cause pressure drops, increased energy consumption, and even rotor seizing. For industries bound by GMP standards, they also compromise compressed air purity—making proactive prevention through proper lubrication, temperature control, and maintenance essential.
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2025-09-16
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