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Volume 30
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Energy Optimization of Compressed Air Systems with Screw Compressors Under Variable Load Conditions

by
Guillermo José Barroso García
1,
José Pedro Monteagudo Yanes
1,
Luis Angel Iturralde Carrera
2,*,
Carlos D. Constantino-Robles
2,
Brenda Juárez Santiago
3,*,
Juan Manuel Olivares Ramírez
3,
Omar Rodriguez Abreo
2 and
Juvenal Rodríguez-Reséndiz
2
1
Centro de Estudios de Energía y Medio Ambiente (CEEMA), Facultad de Ingeniería, Universidad de Cienfuegos “Carlos Rafael Rodríguez”, Cienfuegos 59430, Cuba
2
Facultad de Ingeniería, Universidad Autónoma de Querétaro, Santiago de Querétaro 76010, Mexico
3
División de Ingenierías Mecatrónica, Tecnologías de la Información y Civil, Universidad Tecnológica de San Juan del Río, San Juan del Río, Santiago de Querétaro 76800, Mexico
*
Authors to whom correspondence should be addressed.
Math. Comput. Appl. 2025, 30(5), 107; https://doi.org/10.3390/mca30050107
Submission received: 27 August 2025 / Revised: 20 September 2025 / Accepted: 30 September 2025 / Published: 1 October 2025
(This article belongs to the Special Issue Applied Optimization in Automatic Control and Systems Engineering)
Versions Notes

Abstract

This study evaluates the energy performance of a BOGE C 22-2 oil-injected rotary screw compressor under real industrial conditions. Using direct measurements with a power quality analyzer and thermodynamic modeling, key performance indicators such as compression work, mass flow rate, compressor efficiency, and motor efficiency were determined. The results revealed actual efficiencies of 27–48%, significantly lower than the expected 60–70% for this type of equipment, mainly due to partial-load operation and low airflow demand. A low power factor of approximately 0.72 was also observed, caused by a high share of reactive power consumption. To address these inefficiencies, the study recommends the installation of an automatic capacitor bank to improve power quality and the integration of a secondary variable speed compressor to enhance performance under low-demand conditions. These findings underscore the importance of assessing compressor behavior in real-world environments and implementing techno-economic strategies to increase energy efficiency and reduce industrial electricity consumption.
Keywords: compressor efficiency; rotary screw compressor; energy analysis; power factor correction; variable load operation; industrial energy optimization compressor efficiency; rotary screw compressor; energy analysis; power factor correction; variable load operation; industrial energy optimization

Share and Cite

MDPI and ACS Style

García, G.J.B.; Monteagudo Yanes, J.P.; Carrera, L.A.I.; Constantino-Robles, C.D.; Santiago, B.J.; Olivares Ramírez, J.M.; Rodriguez Abreo, O.; Rodríguez-Reséndiz, J. Energy Optimization of Compressed Air Systems with Screw Compressors Under Variable Load Conditions. Math. Comput. Appl. 2025, 30, 107. https://doi.org/10.3390/mca30050107

AMA Style

García GJB, Monteagudo Yanes JP, Carrera LAI, Constantino-Robles CD, Santiago BJ, Olivares Ramírez JM, Rodriguez Abreo O, Rodríguez-Reséndiz J. Energy Optimization of Compressed Air Systems with Screw Compressors Under Variable Load Conditions. Mathematical and Computational Applications. 2025; 30(5):107. https://doi.org/10.3390/mca30050107

Chicago/Turabian Style

García, Guillermo José Barroso, José Pedro Monteagudo Yanes, Luis Angel Iturralde Carrera, Carlos D. Constantino-Robles, Brenda Juárez Santiago, Juan Manuel Olivares Ramírez, Omar Rodriguez Abreo, and Juvenal Rodríguez-Reséndiz. 2025. "Energy Optimization of Compressed Air Systems with Screw Compressors Under Variable Load Conditions" Mathematical and Computational Applications 30, no. 5: 107. https://doi.org/10.3390/mca30050107

APA Style

García, G. J. B., Monteagudo Yanes, J. P., Carrera, L. A. I., Constantino-Robles, C. D., Santiago, B. J., Olivares Ramírez, J. M., Rodriguez Abreo, O., & Rodríguez-Reséndiz, J. (2025). Energy Optimization of Compressed Air Systems with Screw Compressors Under Variable Load Conditions. Mathematical and Computational Applications, 30(5), 107. https://doi.org/10.3390/mca30050107

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