Experience-based Insights on Selecting Lubricants for High-Energy-Consumption Air Compressors

Created on 2025.12.30
Air compressors are widely used production equipment across various industries and are also high-energy-consuming devices. As a prevalent power source in the industrial sector, compressed air accounts for 10% to 35% of total energy consumption in industrial production. Ninety-six percent of the energy consumption in compressed air systems comes from the electricity consumption of industrial compressors, with annual electricity consumption by industrial compressors in China accounting for over 6% of the country's total electricity consumption. The operating costs of an air compressor consist of procurement costs, maintenance costs, and energy operating costs. According to the life cycle assessment theory, procurement costs only account for about 10%, while energy costs can reach as high as 77%.
If we liken an air compressor to a human body, then the air compressor oil is its blood. Just as poor blood quality can affect overall physical health, using inferior air compressor oil in a high-quality air compressor can lead to problems such as coking and gel formation inside the machine shortly after use, causing the machine head to seize up and rendering the machine inoperable, necessitating a "blood transfusion." In some cases, air compressors may even explode, directly destroying the machine head, at which point a "blood transfusion" is too late, and a new machine must be purchased. Therefore, the selection of air compressor oil directly impacts the machine's performance and lifespan.
As the utilization rate of compressor lubricants increases, so does the frequency of associated malfunctions, with oxidation of air compressor oil being one of the more easily identifiable compressor failures. To improve equipment management levels, prevent dust and impurities from entering the air compressor, reduce component wear, prevent lubricant oxidation, and thereby lower costs, Dinamei Power proposes the concept of "modern equipment lubrication" and details specific requirements for oil selection, storage, and monitoring.
"Optimal energy-saving lubrication" represents a scientific management approach to equipment lubrication, significantly enhancing corporate equipment management levels. It encompasses the entire lifecycle of oil, from selection to replacement and waste oil disposal, involving five primary aspects: oil selection, pollution control, oil monitoring, oil purification, and oil replacement. It refers to the formation of a scientific, practical, and operable equipment lubrication management system through the organic integration of technical and organizational aspects.
Implementing the "optimal energy-saving lubrication" management model aims to address existing issues in equipment lubrication management: replacing current empirical oil selection methods with scientific approaches; creating a favorable lubricant working environment through enhanced pollution control; adopting standardized oil monitoring methods to change the original random and post-event oil testing status; strengthening the purification and maintenance of in-use oil to delay oil degradation; and replacing scheduled oil changes with condition-based oil changes.
The objectives of "optimal energy-saving lubrication" management are to improve equipment efficiency, prevent abnormal shutdowns, reduce equipment failures, decrease maintenance intensity, extend oil change intervals, enhance resource utilization, reduce environmental pollution, and ultimately improve the overall efficiency of the enterprise.

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