How to maintain and improve the air quality of your compressed air system?

Poorly maintained air compressor systems account for approximately $3.2 billion in additional utility costs and inefficiencies, according to the Compressed Air and Gas Association. Maintaining air quality in your compressed air system can save you time and money. But before installing new filters and aftercoolers, it is important to understand the specific needs of an air compressor.

1. Common problems of compressed air system:

Solids, liquids and vapors all affect the smooth and efficient operation of an air compressor system. Particularly common problems are caused by particulates, moisture build-up and lubrication contamination.

(1) Particles

Dust and other small solid materials are present in the air. While this may not have much of an impact on the general environment, it can lead to inefficiencies in the air compression system. and result in insufficient performance. It's also not easy to actually see the particles. The human eye can only see particles about 40 microns or thicker. From this angle, a strand of hair is about 50-70 microns thick. Particles that affect compressor air quality can be as small as 3 microns. Even particles as small as 1/10 of a micron can adversely affect your compression system. The risk of associated particulates in compressed air systems increases with location and reason for use. For example, woodworking workshops generate large amounts of sawdust. Smaller particles can pose a threat to compression systems. Particles primarily damage the endpoints of an air compression system. Compressors that suck in a lot of particles also need more lubrication. Not only is this costly, but it can lead to over-lubrication of the compressor system.

(2) Moisture accumulation

Moisture within a compressed air system can damage pipes and have a catastrophic effect on the efficiency of the system. While an air compressor produces hot air (which can hold higher humidity), when the air is discharged from the compressor, it begins to cool. This in turn causes moisture to accumulate. Moisture can cause pipes to rust, which can damage the system and eventually lead to failure. Even if the pipes are not rusted, moisture can affect the efficiency of an air compressor system. make running costs higher.

(3) Excessive or insufficient lubrication

Some compressed air systems require lubrication to function properly. Failure to lubricate properly (too much or too little) can damage the system. Using poor quality lubricants can also disrupt the compression system and reduce the efficiency of the compressor. Lubricant contamination is a major concern for air compressors used in food production.

Higher end air compressors have more power and more features than economical units. But all types of air compressors run the risk of material damage and poor air quality from particles, moisture build-up and lubrication contamination. Without proper care and maintenance, even the better air compressors run the risk of damage if not properly maintained.

2. Understand air quality needs

So, how to precisely improve the air quality of the air compressor system? The first rule is to determine the level of air quality your air compressor actually needs to achieve. Additional costs may arise from spending too much on filters and drying equipment. It also reduces efficiency where these devices are not needed. There are several ways to determine the required air efficiency of an air compressor system.

(1) Four-level method

This guidance method, provided by the US Department of Energy, is relatively simple and specifies the following items: 1). Factory Air: Used in industrial manufacturing equipment and tools. 2). Instrument Air: Any use related to temperature/humidity control, laboratory work. Spray paint and powder coating. 3). Process air: used for air treatment of food and pharmaceuticals and electronic products. 4). Breathing air: the air system used for respirator, diving cylinder filling, medical air, etc. The last in this taxonomy is the highest level of air quality requirements.

(2) ISO quality class

0 represents the highest quality standard. The table classifies particulates and other contaminants into solids, liquids, and gases (vapors). Especially useful for matching specific filters to your specific needs.

3. Specific Equipment

Both the intended use of the air compressor and the level of filtration required must be defined. This will allow you to take full advantage of the available equipment.

(2) Filter

Maintenance of an air compression system becomes tricky when filters are involved. For example, a Class 2 dust filter will only provide your compressor with air quality at that level of dust. Therefore, if you are concerned about liquid or gas contamination, this filter may not be an adequate product for your system needs. We produce high quality coalescing compressed air filter.

(2) After cooler

The aftercooler works by cooling the air before it reaches the endpoint. Prevents moisture from accumulating at endpoints outside of the compressor. As the air cools, the moisture is removed, keeping the compressed air close to ambient temperature. There are two basic models of aftercoolers. • Air-cooled: A simple system that uses only cold air to extract moisture. • Water-cooled: If you can find a water source, it will be more efficient. Some compressors come standard with an aftercooler.

(3) Compressed air dryer

A dryer can solve the same problem (moisture buildup) as an aftercooler. But the method is different. Instead of cooling the compressed air before it reaches the endpoint, the dryer lowers the dew point so that moisture does not build up. Dryers can be expensive. So make sure your compressor really needs a dryer and buy the right size dryer for your system. Lingyu is top rated manufacturer of refrigerated air dryer and desiccant air dryer.

There is no doubt that regular maintenance of your air compressor system will make it run smoother and more efficiently. However, when it comes to improving compressor air filters, it is more important to understand the needs of the compression system and select the right equipment based on those needs. This way, you can have a high-quality air compressor system that is cost-effective and easy to maintain.

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