Optimization of operating modes of screw compressors: energy efficiency and modern control technologies
Оптимизация режимов работы винтовых компрессоров: энергоэффективность и современные технологии управления
Baskanbayeva D.D. Ismagulova A.Z. Appazova S.M.
2025North Caucasian Institute of Mining and Metallurgy, State Technological University
Sustainable Development of Mountain Territories
2025#17Issue 2929 - 939 pp.
Introduction. This study focuses on enhancing the energy efficiency, operational stability, and ecological sustainability of screw compressor systems widely used in industrial and mining enterprises. Despite significant progress in compressor modernization, challenges remain in adapting operating modes to variable loads, harsh climatic conditions, and high production demands. This work introduces an integrated approach combining experimental testing and mathematical modeling to develop optimized operating modes based on frequency and vector control of induction motor drives. Methods. The methodology combines laboratory experiments on an industrial screw compressor with numerical simulations of drive dynamics in d–q coordinates. Comparative tests were carried out under scalar and vector control modes using precision measurement equipment for electrical, mechanical, and thermal parameters. Statistical analysis, including averaging and confidence interval estimation, was applied to ensure the reliability of results. Additional simulations extended the analysis to scenarios difficult to reproduce experimentally, such as variable load cycles and fluctuating ambient conditions. Results. The findings demonstrate that vector control reduces starting currents by more than 50%, shortens acceleration time by 25%, and lowers bearing and winding temperatures by up to 9 °C compared to scalar control. Specific energy consumption decreased by 7–14% depending on the load profile, while overall system efficiency improved from 77.9 to 82.6%. Vibration levels during startup were nearly halved, and long-term stability under fluctuating load conditions was significantly enhanced. Calculations further showed that annual energy savings can reach up to 18 MWh per unit, resulting in notable cost reductions and extended equipment lifespan. Conclusions. The proposed approach demonstrates the effectiveness of integrating vector-controlled frequency drives into screw compressor systems, ensuring higher energy efficiency, reduced mechanical stress, and improved reliability. The results provide practical recommendations for industrial modernization projects, offering both economic and ecological benefits. The methodology is particularly relevant for mining enterprises with variable demand profiles and contributes to advancing sustainable industrial development in line with Industry 4.0 principles.
frequency and vector control , intelligent monitoring systems , mining transport , neural network modeling , screw compressor systems
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Department of Technological Machines and Equipment, Institute of Energy and Mechanical Engineering named after Burkitbaev, K.I. Satbayev Kazakh National Research Technical University, 22, Satpayeva str., Almaty, 050000, Kazakhstan
Department of Hydrogeology, engineering and oil and gas geology, Institute of Geology and Oil and Gas Engineering named after K. Turysov, K.I. Satbayev Kazakh National Research Technical University, 22, Satpayeva str., Almaty, 050000, Kazakhstan
Kyzylorda University named after Korkyt Ata, 29A, Aiteke Bi str., Kyzylorda, 120000, Kazakhstan
Department of Technological Machines and Equipment
Department of Hydrogeology
Kyzylorda University named after Korkyt Ata
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