Rotary Vane Compressors

vs. Screw Compressors

Page 1 of 16
 Mattei is frequently asked why we manufacture rotary vane compressors, when
most other manufacturers offer screw compressors. We encourage you to continue
reading to learn more about rotary vane compressors and the performance and
efficiency benefits they provide versus traditional rotary screw compressors.

What is Rotary Vane Compressor?

A rotary vane compressor is a volumetric rotary compressor. It consists of a rotor that rotates in a stator,
typically cylindrical - but possibly more complex in shape. The rotor has longitudinal slots with each slot
containing a sliding vane. The rotor is offset in the stator (Figure 1). While the rotor turns on its axis, the
vanes slide within their slots and are pushed against the stator by centrifugal force. Each section of adjacent
vanes encloses a volume of air between them during rotation. This variable volume begins at its maximum
value, corresponding to the maximum entrance of the vanes, and sweeps to its minimum value, at the
point where the stator becomes tangential with the rotor, and vice-versa. The volume within the vanes is
increasing during air intake. This increase in volume naturally draws air from the atmosphere into the pump.
Just as the volume between the vanes reaches its maximum, the vanes seal off the intake. After this, the
volume progressively decreases during the compression stage. Its smallest volume (highest compression)
occurs just as the delivery ports are uncovered by the vanes, forcing the highly compressed air out of the
pump (Figure 2).

FIGURE 1 FIGURE 2
Centrifugal Force Compression – Intake
When the rotor turns, centrifugal force holds the blades During the air intake phase, the air volume between two
against the internal wall of the stator, which ensures adjacent blades passes from the minimal value at the
perfect sealing of the air. closest tolerance of the rotor in relation to the stator, to the
maximum capacity in the diametrically opposed zone, and
vice-versa during the compression phase.

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What is a Screw Compressor?
The screw compressor is also a volumetric
rotary compressor. It is composed of two parallel
rotors with external helical profiles (screws). This
enables the two rotors to engage smoothly, one
into the other. The two rotors are closely fitted in
a stator made from two cylinders which intersect
longitudinally and in which the rotors turn with a
highly critical minimum clearance (Figure 3). The
rotor shafts are supported by roller bearings and
generally, one rotor drives the other by means of
the interlocking helical profiles. Sometimes, they
are driven by a pair of external gears. Although this FIGURE 3
can drive more power into the system, it requires The rotors are fitted in a stator made from
that the two motors be fully synchronized. During two cylinders which intersect longitudinally
rotation, the screw profiles uncover an intake and in which the rotors turn with the
orifice at one end of the stator. As the profiles minimum clearance.
open up across this orifice, it draws air into the
expanding volume between the profiles. This air
is then separated between the two screws and
trapped against the stator wall as they rotate
around their axis. On the opposite side, the screw
profiles penetrate into each other, reducing the
volume, compressing the air and delivering it to the
uncovered outlet port.

Basic Similarities & Differences Volumetric Efficiency

Although the rotary mechanisms are different, most The relationship between the effective air delivery
of the other components required for the operation and the geometric volume defines the volumetric
of the compressors, such as oil coolant, separator, efficiency of a system. This efficiency is affected in
pressure regulating valves, non-return valves, etc., each rotor stator unit by air leakage. This is most
are common for both vane and screw compressors. critical in the area under the highest pressure towards
The difference is in the compressor design adopted the intake. It is important that these leakages be
by each manufacturer, based on technical, economic kept to an absolute minimum. The energy required
and aesthetic considerations. This comparison will be to recompress air that leaks near the intake, is a
limited to the vane and screw mechanisms, which are loss. The smaller the internal leakage, the more the
at the heart of each compressor. volumetric efficiency increases and the required
power per measuring unit of delivered air is reduced
(specific energy).

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Air Escape along the Stator Surface
In a rotary vane compressor, the vanes are always in Furthermore, the large volume of oil injected into
contact with the internal surface of the stator (Figure the stator lubricates the moving parts and cools
1). The air seal is practically perfect. Because of the air during compression. It also seals the
minimum clearances due to machining tolerances clearances between the rotor, stator and end covers.
and operation of the set, there is a slight possibility It is along the surface where the rotor touches the
of escape along the surface where the rotor is at a stator (tangent point) that the oil, pushed by the air
tangent to the stator. Even when there is just one pressure, slips into the space between the delivery
vane (Figure 4) between the delivery and the intake ports and the adjacent blade and seals it (Figure 5).
ports, this vane will prevent the air escaping from This is not the case in a screw compressor, where
high to low pressure. In practice, the air leakage there must be a minimum clearance between the
is greatest in a new rotary vane compressor when external profile of the rotors and the internal surface
compared to older, well maintained, compressors. of the stator. This is necessary to allow the rotors to
Over time, as the vanes sweep along the stator they turn without touching the stator walls. It is, therefore,
begin to wear down any irregularities or machining unavoidable that a certain volume of air leaks from
defects along the wall. This creates a process the high pressure to the low-pressure area in a rotary
wherein the air seal becomes tighter over time. screw compressor. This can only be limited but never
eliminated, even by high precision machining (Figure
6).

FIGURE 4 FIGURE 5 FIGURE 6

One blade between the intake One blade between the intake Screw compressors need a
and delivery port will prevent the and delivery port will prevent the very high degree of machining
air from passing from the high air from passing from the high accuracy, otherwise the rotors
pressure to the low-pressure side. pressure to the low-pressure side. might touch and seize or the
compressor has a very low
operating efficiency.

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Leakage along the Side Planes
Due to its geometry, the air under pressure in a screw compressor produces axial thrust. This makes the
rotors reduce their side clearance at the intake side, but increases its clearance at the delivery side, where
sealing is most critical (Figure 7). The side thrust is borne by roller bearings, preventing the rotors from
touching the surface of the end cover. The air sealing maintains itself due to resistance, the quality of the
bearings, as well as the machining accuracy of the couplings.

The vane compressor has no axial thrust pushing the rotor against either end cover. It is, therefore,
unnecessary to control its axial position by means of bearings or thrust bearings. The rotor is free to move
axially and is kept equally spaced from the end covers by means of an oil film, which comes out, under
pressure, through holes in the end covers. This film prevents contact and provides efficient sealing (Figure 8).

Gap on intake side

Gap on outlet side

FIGURE 7 FIGURE 8
In a screw compressor, the air under pressure produces There is no axial thrust in a rotary vane compressor. The
axial thrust, which reduces the clearance at the intake rotor is free to move axially and is kept equally spaced
side and increases the clearance at the delivery side from the end covers by means of an oil film, which is
where sealing is most critical. injected under pressure. The injected oil prevents the air
from escaping along the side planes.

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“Blow Hole”
The “blow hole” is unique to the screw compressor. It does not exist in a vane compressor. The “blow hole”
is a gap where the profiles of the rotors meet at the intersection of the cylinders in which they rotate (Figure
9). The geometries of the screws create this gap, in the exact location where the air under the greatest
pressure is able to return to the area of lowest pressure. This technical problem is caused by the geometry
of the screw compressors. All screw manufacturers have tried to reduce the effect of the “blow hole” by
analyzing and redesigning rotor profiles to create smaller openings at this crucial point. However, the “blow
holes” complete elimination is impossible.

It is possible to partially solve this problem by increasing the

rotational velocity of the rotors. This maintains the level of escape
while increasing the air delivery. However, an increase in speed
requires an increase of specific energy, higher wear and a shorter life
span of the compressor. In air sealing and volumetric efficiency, the
vane compressor is superior to the screw compressor. The volumetric
efficiency of Mattei compressors is approximately 90%.

FIGURE 9
The “blow hole” in a screw compressor is where the external profiles of the rotors meet at the intersection of the
cylinders in which they rotate. The air under pressure returns to an area of lower pressure through this hole.

Energy Consumption
This is the most important feature of any air compressor. It is defined by the energy required to compress a
given volume of air to a certain pressure. Manufacturers continue to attempt to produce compressors with
the lowest possible energy consumption. This results in higher compressor efficiency and lower operating
costs for the user. Often highly efficient models can offset their purchasing costs by the accumulated energy
savings in just a few years.

One of the greatest energy loses in a compressor is internal air leakages. It is vital to keep these as small
as possible, because the air lost during compression is lost energy. During the compression cycle, the
air warms, as is defined by the Ideal Gas Law. With the increase in temperature comes an increase in the
specific energy required to continue compressing the gas. This depends on the efficiency of cooling the
system. In theory, the most efficient method of the reducing energy requirements is when compression
occurs at a steady temperature with sufficient cooling. The more efficient the air-cooling the lower the power
required.

Both vane and screw compressors are oil injected for cooling. The cooling takes place by introducing oil
into the stator during the compression stage. This oil is introduced at a lower temperature than the air
temperature. This process is the same for both vane and screw machines. The oil cooling systems can
be evaluated by the temperature of the oil: the lower the oil temperature the better the thermodynamic
efficiency of the compressor.

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Friction & Power Loss
Mechanical losses due to friction and power transmission increase with rotational speed. Screw
compressors must run at high speeds to reduce the problems of unavoidable air leakages whilst vane
compressors can work at comparatively lower speeds without encountering the same issues. A vane
compressor can run at 1000 rpm while the average screw compressor must run at 3000 rpm. This is a
great advantage for vane compressors as far as power consumption is concerned. Additionally, screw
compressors are often fitted with speed increasing gears or belt transmissions to boost the screw speed,
with respect to the electric motor (Figure 10). These gears cause additional energy losses as the power
absorbed can exceed 5% of the transmitted power.

FIGURE 10
Because of low volumetric efficiency, screw compressors are fitted with gears or pulleys to increase rotor
speed.

Vane compressors will work efficiently at the same speed as the electric motor. The compressor is
connected to the electric motor with a flexible coupling, which does not cause any power loss (Figure 11).

FIGURE 11
Rotary vane compressors work at the same speed as electric motors. They are connected to the electric motors
through flexible couplings, which do not cause any power loss.

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Friction & Power Loss (Continued)
In order to better compare a vane or a screw compressor it is important to know the specific energy
requirements at a given delivery pressure. Unfortunately, many factors are difficult to obtain when trying to
make this comparison.

First, manufacturers rarely state the actual power absorbed by their compressor and they usually only
quote the rated motor output. Many times this is lower than the absorbed power because the electric
motor is overloaded in comparison with the rated output (service factor).

Second, some compressors are cooled by an auxiliary fan fitted directly onto the compressor shaft,
while on others the fan is driven by a separate electric motor. In this case, one has to consider the
power adsorbed by the fan and add it to the total required power.

Third, the stated performance might refer to the air end only without the necessary air filters and
separation or to the complete unit including all fittings needed for operation of the compressor. The air
filter restricts the air inlet and reduces the airflow creating energy drag on the system as well.

Fourth, all other fittings downstream of the air end, such as oil separator, non-return valve, after cooler
and condensate separator will cause a significant drop in air pressure. Therefore, the power required
by the compressor will be lower if the delivery pressure refers only to the outlet from the air-end
instead of downstream of the complete unit.

The average specific energy of a MATTEI rotary vane compressor of the latest generation, including the
cooling fan, is 15.49 kW per 100 cfm of free air delivered at the delivery pressure of 115 psi(a) measured
downstream of the moisture separator.

ISO specification 1217 gives a 5% allowance on the declared air delivery, and a 6% allowance on the
specific energy. The specific energy for a compressor must be clearly stated. It can be roughly calculated
by dividing the rated output quoted by the declared air delivery. However, since the rated output can be off
by as much as 15% and the declared air-delivery usually has an error of 5%, an unrealistic value is easily
calculated, being as much as 20% less than the actual energy required.

The quality of the performance of every Mattei rotary vane compressor is the same, without any significant
differences between the various models – besides the obvious. The free air delivery is not affected by
the machining accuracy or by the clearances between the fixed and rotating parts. The vanes, moved
by centrifugal force, are constantly in contact with the stator and always seal (Figure 12). Even the axial
clearances do not need great accuracy because they are sealed by the oil, which is injected under pressure
through the rotor planes, and side covers (Figure 8).
In a screw compressor, the air seal is extremely sensitive to the accuracy of the machining of the rotor (the
rotors should perfectly seal along the contact line). The accuracy of the center distance, to the clearance
between the two rotors and the stator, as well as to the axial clearance, which is regulated by the thrust
bearings (Figure 6). There can be large differences between the operating capabilities within the same
models of screw compressors, based solely on the precision of their machined rotors. For this reason, we
talk about first choice and second choice screw compressors.

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Reliability & Operating Life Expectancy
Time does not reduce the performance of a well-maintained rotary vane compressor. Their rounded edges
and abundant lubrication during rotation ensure the vanes slide on an oil film preventing direct contact with
the internal surface of the stator. This results in only negligible wear on the vanes. The working life of the
vanes is practically unlimited: they can operate for over 100,000 hours (2 to 3 times that of rotary screw
compressors) without wear. In fact, some Mattei vane compressors have been known to last well over
230,000 hours. Even a slight wear to the vanes does not affect the seal. The vanes are made with a great
degree of freedom to slide in the rotor slots, this is the reason they are always in contact with the stator
(Figure 12).

In a rotary screw compressor, the rotors FIGURE 12 - 13

are subject to friction on the flutes, due to Rotary vane compressors work at the same speed as electric motors.
the thrust caused by the male rotor on the They are connected to the electric motors through flexible couplings,
female rotor when rotating. As the contact which do not cause any power loss.
between the two rotors occurs along a
tangential line, meaning very limited surface
contact, the specific pressure can be so
high as to break the lubricating oil film. If this
occurs, metal will grind on metal and wear is
unavoidable! (Figure 14).

To reiterate, a rotary vane compressor has

no axial thrust and therefore no wear on
the side surfaces of the rotor against the
cover plates (Figure 8). Furthermore, there is
no contact between the rotor and the stator. The internal oil pressure prevents the rotor from touching the
stator (Figure 15). The same cannot be said for rotary screw compressors. The minimum clearance and the
control of the axial thrust depend on the bearing fitted onto the rotor shafts, which turn with the minimum
clearance. Should there be the slightest wear or relaxation of the bearings, the rotor would be pushed by
pressure against the opposite side and touch the stator. This contact can result in severe consequences
(Figure 16).

FIGURE 14
In a screw compressor, the air under pressure produces
axial thrust, which reduces the clearance at the
intake side and increases the clearance at the
delivery side where sealing is most critical.

FIGURE 15
Internal oil pressure prevents the rotor from
making contact with the stator wall.

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Simplicity of Design
In a vane compressor, the rotor shaft is supported by white metal bearings, which ensure a quiet and longer
operating life than compressors with roller bearings, as are seen in screw compressors. Roller or taper
bearings are needed in a screw compressor because the rotors have to operate at high speed with high
axial accuracy and minimal clearances between the rotors, housing and endplates. If the two screws touch
or make contact with the stator, the compressor will seize (Figure 17).

It is common to need to replace screw compressors bearings after only 24,000 hours of operation. With a
vane compressor, the rotor diameter is smaller than the stator diameter, and therefore an increase of the
clearance between shaft and bearings is of no importance. During rotations, the vanes simply follow the
cylinder profile and will never jam (Figure 18). Lubrication of the bearings is ensured by oil under innate
pressure, without the requirement of any mechanical circulating pump, removing any risk of pump failure.
It can be said that lubrication is proportional to the air pressure and consequently to the radial loads
generated by the same: the higher the air pressure the more oil will be injected and the higher the oil
pressure.

FIGURE 16 FIGURE 17
As soon as the roller or taper bearings If the two rotors make contact, or touch,
start wearing in a screw compressor, radial the stator the compressor will seize.
pressure pushes the rotors against the
diametrically opposite sides of the cylinder.

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Metal Forming
The machining of the rotors for screw compressors must be carried out with special and expensive machine
tools. The rotors of the screw compressor need to be made from very easily machinable steel. This is due
to the large amount of metal removal and numerous machining operations required to form them. This type
of steel is prone to galling under marginal lubrication conditions. Screw rotors that have been in service for
under 2000 hours will have gaps and scars on surfaces. A screw compressor is at its most efficient when it
is new. The clearances and leakages are at a minimum. As the compressor wears, the clearances enlarge.

Machining of any part of the vane compressor can be performed with quality machine tools to ensure
accuracy and inter-changeability of the parts. Any component in a vane compressor can be replaced
without changing the part to which it is adjacent. This is not the same for screw compressors: the rotors are
a ‘matched pair’. A vane compressor is made from high quality cast iron. Cast iron is a perfect material for
compressors. The highly porous surface retains oil protecting it at every engagement. Due to its geometry
and metal configuration, the vane compressor actually improves with usage. With time, the blades will
settle in on the stator and rotor slots. This reduces leakage and increase power efficiency. Eventually the
compressor stabilizes at a level 5 to 10% higher efficiency than when new.

Repair Costs
In screw compressors, the wearing parts are normally the rotors, the roller bearings, the gearbox, bearings
and even the stator. Due to the inevitable wear of the bearings, the rotors eventually touch the cylinders
in which they rotate. When this occurs the air end will require replacement. The failure of the air-end can
cost up to forty percent of the cost of a brand new unit, while a full set of vane compressor blades costs
less than 10 percent. Due to the additional cost of the screw air-end, there is usually a wait of several
days or weeks, as the parts need to be ordered and manufactured
on-demand. Whereas the vane compressor parts are inexpensive
enough that dealers usually carry them on the shelf.

FIGURE 18
During rotation, the vanes follow the cylinder profile.

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Why Choose a Mattei Rotary Vane Compressor?
The design of Mattei compressors is the result of more than 50 years’ experience in the field of rotary
vane compressors. They produce some of the most energy efficient air and gas compressors in the world.
Located in Baltimore, Maryland, their products are supplied throughout North and South America to
collision repair distributors, body shops and other industrial air users, for applications where energy costs,
reliability and clean dry air are critical. Mattei continues to improve both the performance and operation
of their signature rotary vane compressors, where they distinguish themselves by their design, the main
features of which are their modern, compact and quiet operation.

In Mattei compressors, all main components, such as oil chamber, separator, air filter, non-return and
pressure regulating valve, are an integral part of the machine and make up a single unit. The compressors
are directly connected to the electric motor forming a single unit. The cooling assembly, including both oil
cooler and after cooler, is mounted behind the electric motor. These compressors are “ready-for-use” air
stations, only needing to be connected to the electrics and air main prior to operation.

Product Quality
Quality is ensured in Mattei compressors by the use of the best possible materials, irrespective of cost. The
rotors are made from spheroidal cast iron, the stator from meehanite cast iron and the vanes from special cast
iron to ensure long operating life and stability. The vanes are lightened by deep parallel holes with a curved
surface, easing their slide within the stator slots. These are real mechanical “jewels.”

The vane compressor accessories are of high quality as well: the dry air filter with paper element; the oil
separator made from borosilicate fibers; oil and compressed air radiators made from aluminum; the coupling
is flexible with rubber elements and all O-rings are made from viton.

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Performance of Mattei Compressors
The required power for a given unit of delivered air in Mattei rotary compressors is amongst the lowest that
can be found in any modern screw or vane compressor. This is due to the continuous improvements of the
rotor/stator unit. Mattei compressors have reached a power requirement of 15.49 kW per 100 cfm of free air
delivered at the delivery pressure of 115 psi(a) (Maxima). If the compressor is tested without cooling fan and
intake filter, as many compressor manufacturers do, the power consumption is reduced to 12.516 kW per
100 cfm.

Since the compressors and its accessories are designed with the efficiency of a single unit. Special
attention is paid to the size of the air treatment equipment downstream of the compressor, such as oil
separator, non-return valve, air final cooler, condensate separator and relevant connecting pipe, which
are required for the final treatment of the compressed air. These are all designed specifically to reduce
the pressure drop, because, the higher the pressure drop the higher the energy consumption. In Mattei
Compressors, all fittings are an integral part of the compressor. The total pressure drop from these fittings
is between 4-6 psig. The power required to compensate for this pressure drop does not exceed 3% of the
total power requirement (Figure 19). This is better than most other makes of compressor.

FIGURE 19: With Mattei compressors, the pressure drop through downstream fitting is minimal.

kw/100 SPECIFIC ENERGY REQUIREMENTS (MAXIMA)

cfm

19.8

16.9 1
2

14.1
1. Line pressure with downstream equipment fitted
2. Bare compressor

11.3

87 102 116 130 145 psi (g)

102 116 130 145 159 psi (a)

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Oil Separation & Air Cooling
In Mattei compressors, the oil separation occurs in several stages and gives an exceptionally low oil
carryover. The primary separation occurs in the oil chamber, at the outlet of the rotor/stator unit, along
a labyrinth made by the external fins of the stator and the internal fins of the oil chamber. Secondary
separation occurs at the inlet of the final separator, before the separator elements through the expansion
and change in direction of the airflow. The final separation is effected through the filters themselves,
removing the remaining oil vapor from the compressed air. This is a unique separation system not found in
other makes of compressors. By installing final oil removing filters, Mattei rotary vane compressors can be
used in oil-free applications.

Effective oil cooling is imperative to the design of an air compressor, both for the performance (air delivered
and power required) and for the safe operation of the compressor. By keeping the oil temperature low, its
lubricating properties remain unchanged for extended periods, and the gaskets and seals will keep their
flexibility for longer. This reduces the need for maintenance or repairs and the compressor will have a longer
lifetime.

The oil temperature of Mattei air-cooled compressors normally does not exceed 55°C over ambient. This
means that Mattei compressors can safely operate even at an ambient temperature of 45-50°C. On the
other hand, it is always advisable that the oil temperature remain at the designated operating temperature,
to ensure the efficient operation of the compressor and avoid condensation under particular operating
conditions. Mattei compressors are also equipped with thermostatic valves, ensuring that the oil rapidly
reaches its efficient working temperature.

In compressors without after coolers, the compressed air leaving the compressor is 44°C above ambient.
In compressors with after coolers, the temperature of the air leaving the compressor is only 4-6°C above
ambient. The more efficient the cooling of the compressed air, the more efficient will be the separation
and removal of condensed water. All Mattei compressors are equipped with condensate separators and
automatic drains. These systems remove over 70% of the water from the compressed air.

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Capacity Regulation & Energy Saving Under Partial Load
In order to obtain the maximum energy saving under partial load conditions (for air demands lower than
effective capacity), Mattei compressors are equipped with combined regulation regimes, occurring in three
stages (Figure 20).

The first stage is the continuous modulated flow, obtained by throttling the intake valve of the
compressor, based on the air demand. This is most convenient when the air demand exceeds two
thirds of the compressor capacity. It keeps the delivery pressure steady to avoid excessive energy
losses due to the frequent starting and stopping of the compressor.

The second stage operates the ‘on load - off load’ with depressurization or blow down. When the
air demand decreases the compressor turns automatically to the ‘off load’ regulation. The intake
then shuts completely at a set pressure and consequently the compressor runs off load until the line
pressure falls to a minimum set value. By exhausting the internal pressure, it reduces the energy
consumption during off load operation.

The third stage occurs when air delivery is further reduced, normally to one-third of the free air
delivery, and the air demand is satisfied. The compressor will stop at this stage. This choice is
made automatically by a timer that detects the speed at which the line pressure falls during off load
operation. It only stops the motor after a set time if the pressure maintains over a fixed value.

FIGURE 20: Energy savings through automatic selection of the mode of regulation.

Capacity % AIR DEMAND - ENERGY REQUIREMENT

100

75

50

25

Automatic start/stop Automatic on/off operation with Continuous regulation

operation internal depressurization through modulation

0 25 50 75 100 Output %

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Maintenance & Overhaul
Assembling and dismantling of Mattei compressors can be carried out quickly by using standard tools.
It also made easier by the lightweight of the main components, the majority of which are made from
aluminum. The ease of dismantling the machine into subassemblies, such as rotor/stator unit, regulating
valves, oil separator, cooler, etc., makes fault diagnosis simple and routine. The only preventative
maintenance required is to change the oil, clean or replace the air and oil filters and clean the radiators.

About Mattei
Mattei pioneered the development of the rotary vane compressor in 1958. For more than 50 years, these
machines have been used worldwide. Recent patents generated by Mattei’s Research & Development
Department are evidence of our drive to continually exploit proprietary vane technology and its performance
and efficiency benefits, versus traditional rotary screw compressor systems.

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