Air compressors play a unique yet very important role in the fabric of smooth and successful industrial operations. Air compressors are machines that escalate the volume of air which is stored within a particular space. While holding volumes of air, the pressure is relatively increased. This produces a force that is commonly utilized for a range of application. The applications are usually by industries in manufacturing, commercial and even personal use.

There are several types of air compressors present today in the market. Basically, air compressors intended for industrial use are categorized in two forms: dynamic or positive displacement. Each type is defined through their primary mode of application.

Now, used industrial air compressors aren't something that most prospecting buyers would think about. When you are about to purchase something such as this, you apparently assume that you'll be purchasing a brand new unit for your business since that is what you know is the only option. However, when you are searching for holes in which you can squeeze some savings, a used model may suffice.

There are tremendous amounts of benefits in purchasing an industrial air compressor that is pre-owned, regardless of what your needs or demands are for an air compressor. If you are considering on purchasing and investing on a used industrial air compressor, your priorities should be what the quality of the used unit will be like. It is only normal to imagine about whether or not you can really obtain a mint condition air compressor unit with a cheaper price tag. To do so, you should take the time and the effort in researching for the best leads and sources in which to purchase an air compressor.

If you are able to purchase and bet on the right places, it is indeed possible to get an air compressor with the same quality as a brand new one yet with a much cheaper price. Another gain you get from purchasing used industrial air compressors is that your range of options is broader. Also, the chance for getting better and more advanced models are increased since you have more money to shell out. There are tons of uses and applications that an air compressor can play as for your business and having a unit around your business will always be a benefit for you. Given some know-how and doing your homework correctly, you can obtain everything that you need. At the same time you can invest a portion of your funds into a used air compressor.

Designing a new compressed air system includes hiring a professional engineer to complete an Air Demand Analysis to customize the system according to your needs and usage in order to optimize performance and efficiency. The professional engineer will perform a series of tests and use that information to create a detailed analysis, which will help develop a compressed air system for you that has environmental, energy, and cost benefits.

Accurate and valuable data will be gathered throughout the process that will be used to optimize your system. Air consumption profiles will determine which system is best suited for your operation. Everything including the type of compressor and its layout is completely tailored and designed case-by-case. This step is highly recommended due to the amount of energy savings it guarantees, which translates into a significant amount of money saved over time.

Energy costs can be significantly reduced when an Air Demand Analysis accompanies a new system. This is significant because electricity is by far the highest cost of operating it. The goal of the process is to meet all your requirements while keeping the amount of pressure used to a minimum. This is achieved by matching you with the appropriate device and then customizing its features and layout.

The Air Demand Analysis consists of a few steps. First, air demand and other data is collected. Second, that data is used to appoint the best systems. Third, each system is tested vigorously to determine its power consumption and overall efficiency when faced with the variables of your working operation. Fourth, the best system is selected and then tailored to fit. It is even possible for you to view a detailed 3D image of your system before it is installed.

The professional engineer will be able to provide a realistic prediction of energy savings. You will have the opportunity to compare the extremes of having an Air Analysis and not having one to get a true picture of its necessity. The best systems are durable and have optimal performance. The professional will do everything to ensure you have the best system.

An Air Demand Analysis is a very important step when designing and selecting a compressed air system. A professional engineer or vendor will perform tests to determine the system that will perform best in your environment and save the greatest amount on energy. It will be completely designed and tailored to your needs to ensure maximum performance, reliability, and efficiency.

Moisture can damage an air compressor by running through the system’s hoses. Fortunately, there are refrigerated air dryers that serve to remove moisture from compressed air systems. In order to maintain these units, it is necessary to install an appropriately sized refrigerated air dryer.

A common entry point for moisture tends to be the air compressor’s inlet air filter. Standard air compressors can convert up to seven cubic feet of air to 100 psig per single cubic foot, compressing water vapor within the air to that size.
Water that becomes contained within compressed air comes in different forms, including mist, vapor, gas or liquid. A general purpose filter may be used with a compressed air system to remove liquid water, with remaining water that is either mist or vapor removed by the refrigerated air dryer.

Refrigerated air dryers can also prevent contamination on equipment located downstream from the air compressor. Water contamination can cause moving parts to fail, reducing the holding capacity of airborne moisture by fifty percent when the temperature drops below fifty degrees, leading to costly repairs.

The process the refrigerated air dryer goes through begins with the use of an air to air heat exchanger, which cools the compressed air. The heat exchanger then condenses moisture by small amounts, cooling incoming air and sending it to an air-to-refrigerant exchanger that cools it even further via liquid refrigerant. Remaining moisture is condensed into a liquid that is drained from the system. The air is then finally heated inside a heat exchanger to prevent the hose’s pipe from sweating.

When searching for the perfect refrigerated air dryer, keep the pressure dew point in mind. The pressure dew point is the temperature required in order for water vapor or mist to condense into liquid. The most often used pressure dew point class is Class 4. To determine the pressure dew point class of your unit, as well as temperature requirements, have a test of equipment performed.

Most people who have an industrial air compressor will own or have owned a refrigerated air dryer, which is one of the most common components used when removing moisture from compressed air systems. There is a large number of different types and styles of refrigerated air dryers on the market today, so you need to be sure you know what you are looking for. When trying to purchase an air dryer to install in your system, you must consider the initial cost, reliability and long-term operating expenses of the potential choice of dryer.

A refrigerated air dryer simply uses a heat exchanger and a refrigeration system to reduce the temperature of the air within the air compressor. This, then, causes any moisture to condense outside of the machine. After this has happened, the moisture is separated and discharged from the air compressor using one of various methods. Because these methods vary from one kind of air dryer to the next, the particular method used is determined by the type of dryer that one owns.

One of these types is an energy saving air dryer. This kind has the ability to unload or turn off the refrigeration side of the dryer when it is going through periods of low activity. This not only reduces the overall energy consumption of the machine (therefore lowering the cost of using it), but can also add to the longevity and reliability of the dryer because it is not constantly being used at its maximum capacity. There are many different styles of energy efficient dryers available for someone to use. Some of these include dual control dryers, thermal mass dryers, and flooded evaporator dryers. Conditions of the area surrounding the intended location of the air dryer, as well as the condition of that location and the size of the dryer, will all play a big role in selecting the right dryer for your plant.

The modern generation of energy saving refrigerated dryers have design features that not only allow them to use up to a third less energy during performance than previous models, but also a tenth less energy when simply standing idle. Many of these dryers are also constructed to be environmentally friendly and have a low ozone impact. By combining the essentials of a refrigerated air dryer with an updated, cost effective and energy saving model, a company can not only save money in electrical costs, but can also add longevity and reliability to their system.

Anyone who owns an air compressor understands the importance of properly maintaining their machine. A crucial tool in this process is a condensate management system. So long as these systems are functional, they are very important components of all air compressor systems because they separate the small amount of oil from the condensate that gathers in the air compressors. This allows the caretakers of the air compressor to perform simple, ecological, and economical disposal of any leftover waste.

Since unwanted and excess oil can be a serious problem in an air compressor system, oil and water separators or condensate managements systems are installed to reduce the waste oil concentration. However, before disposing of this oil into the sewer, you must make sure to reduce it to legal limits. If you do not do this, you could be harshly punished for disobeying the law and potentially poisoning the nearby environment. Most separators naturally reduce the oil to a level permitted for disposal, but always check with your local municipality to be sure everything is alright. It is also good practice to periodically send out a sample of the reduced oil for analysis, in order to be confident that you are correctly following the rules.

In the past, people would use a waste management company to come and remove collected condensate from their site. This, however, came only at a considerable cost. Today there are a number of different types of condensate management systems which can used independently within a company, and can separate almost any compressor fluid from the condensate. This allows the 98% of the condensate that is solely water to be disposed on site. The small percentage of remaining oil can then be collected and recycled, or disposed of at a much cheaper rate than what was possible before.

When one owns an industrial air compressor, there are many benefits of using a condensate management system to maintain and clean it. One of these benefits is that these systems will protect your air compressor from damage by removing harmful excess oils. You will also ensure that the compressed air that is being delivered to your company is clean, protecting your product from any possible harm. You will also be saving a great amount of money in waste removal and fines, because you can clean your air compressors without the help of a second party. Finally, condensate management systems allow companies to be environmentally conscious and safe during waste disposal by removing any toxic oils from water that could otherwise be safely drained into the environment.

Filters are an important component for your industrial air compressor system to remove contaminants and purify the air in the system. Choosing the right type of filter depends on the requirements of your system and the maintenance you wish to complete.

Oil flooded screw compressors are highly regarded as a reliable and cost effective system. However, it is imperative to find the proper filter to remove the contaminants, oil and atmospheric dust, that oil flooded compressors introduce into the compressed air. Coalescing filters are appropriate for removing oil mist from compressed air and automatic drain valves can eliminate the liquid condensate. Both filters require replacement when they are filled with dust.

Air compressor systems require aerosol filtration upstream of the compressed air dryer, after the air dryer and downstream at each point-of-use. Dessicant dryers and refrigerated dryers should utilize both a prefilter and an afterfilter to remove liquid and particulate aerosols. The filtration units will also prevent adsorbent fouling in dessicant dryers and the fouling of the heat exchangers in the refrigerated dryer. The downstream filter is responsible for removing the adsorbent fines from the dessicant dryer and water mist from the refrigerated dryer.

Selecting the right compressed air filter depends on the needs of your system. A high particulate filter operates under high temperatures, up to 450 degrees Fahrenheit, and offers a high level of protection against fire in a heated dessicant dryer. Vapor, or charcoal, filters are suggested for the removal of organics from hydrocarbons and chemical vapors. A particulate filter is used in dessicant dryers to remove scale, metal oxides and dessicant particles.

Compressed air filters are necessary to maintain clean air as they remove harmful materials from the unit. Particulates that need to be filtrated include scale, metal oxides and dirt because they can decrease efficiency, damage finished products and erode system components. Chemical gases, such as chlorine, sulfur, carbon dioxide and carbon monoxide, need to be filtered as they can pose a threat to the health and safety of workers. Microbes, molds and fungus can grow within a moist air system and may produce an acidic waste which is corrosive and can cause pipes and valves to clog with sludge. Finding the right filter for your industrial air compressor can help increase the efficiency of your unit. It will also lower your energy costs and protect your employees from harmful particles and chemicals.

The basics of compressed air are very simple. Compressed air is just air kept under pressure that is greater than the atmosphere. The technology of compressed air has been around for decades, but as with any technology, it has developed. Not only is it widely used commercially and residentially, but the industrial applications of compressed air technology are immense.

An air compressor works similar to that of your car engine. In your car engine, pistons push down on an air and gasoline mixture. The mixture compresses and it then ignited which produces power. In the simplest form, an air compressor does the same thing. A piston in the compressor pushes air down, pressurizing it, and stores it in the tank underneath. Because of technology, the air compressor used today is able to store large amounts of pressurized air in its tanks.

Industry requires air compressors for many of their uses. For example, air compressors are used for air driven tools like paint sprayers, sanders, drills, etc. This is especially common in automotive shops where compressed air is run throughout, allowing easy access from the different car bays. In the home, air compressors can be found inflating toys, pools, car tires, and even powering some pneumatic tools. Because the technology has developed, the demand has grown, and the price has gone down over the years, many more homes now have air compressors. Typically, home air compressors are smaller than industrial models. The tools for these air compressors are sometimes sold with them, or can be easily bought locally, making the convenience of having a personal air compressor real. Pressure washers are perfect examples for air compressors. A pressure washer consists of an air compressor and a garden hose attached, combining the water and pressurized air to make pressurized water. This is used often for cleaning concrete, cars, siding and decks.

A newer use for compressed air has been with consumer electronics, especially computers. Computers, due to their static nature, attract large amounts of dust which may cause the computer to not work properly or sometimes not even at all. Compressed air can be found in cans with a straw to direct the air, and is easily used to clean the outside and inside of a computer, television, or even the dashboard of a car.

Air compressor technology has been dramatically upgraded over the decades. Because of technology advancements in manufacturing, now air compressors can be made to very specific measurements. Improvements on already existing parts in the air compressor have all but solved any air or oil leakage issues of the past.

When choosing an air compressor, make sure to pick one that is powerful enough to meet your needs or those of your business. Take into consideration an air compressor’s airflow and pressure when comparing compressors.

There are three main types of air compressors: rotary screw, reciprocating and centrifugal, or dynamic, compressors. Screw and reciprocating compressors are positive displacement machines. Reciprocating compressors use a piston within a cylinder to increase the pressure of the air by reducing volume, while screw compressors use intermeshing screws that force air into a smaller and smaller space.

Unlike rotary and reciprocating air compressors, a centrifugal air compressor is a dynamic system. A
dynamic compressor increases air pressure using impellers – rotating disks - as well as a diffuser to convert velocity energy to pressure energy. It has the distinct advantage of being an oil-free air compressing system.

Progressive stages are used to increase the pressurization of the air to the desired level, driven by an electric motor or a steam or gas turbine. Because centrifugal compressors compress air in stages, the air being compressed stays cooler and the air compressor is more efficient, both mechanically and in terms of the energy being used.

Centrifugal air compressors usually operate at a high minimum speed. They are also capable of running continuously for long periods of time. They are often found in manufacturing plants, automobiles, and in gas, oil and refining industries. These compressors can also handle large flow rates, and these kinds of compressor can be some of the most efficient and consistent air compressors available. Centrifugal air compressors are often very compact as well.

Centrifugal air compressor systems are a great fit for industrial settings, as they produce a constant flow of high-pressured air to meet high demands. The rotating impeller system means that centrifugal air compressors are able to provide continuous air flow. Other benefits are that centrifugal compressors provide oil-free compressed air, and because of their few wearing parts tend to be very low maintenance as well. Centrifugal air compressor systems are also usually very compact.

Among the many benefits of a centrifugal air compressor are its simple design, its ability to produce oil-free air for sensitive applications such as the food and beverage industry, and its ability to produce high volumes of air. Although centrifugal compressors often have a high initial cost, this is usually compensated for by their long and relatively low-maintenance life.

Air compressors can provide a great source of heat when converted from electrical energy. With the increase in electric costs, recovering heat from air compressors is more important than ever in having an efficient air system.
The transference and transportation of heat from a medium to a compartment where it can be utilized is the guiding principle of heat recovery.

Heat can be recovered from electrical energy from three parts of a screw compressor: the fluid cooler, the aftercooler and the drive motor. The heat recovered from both the fluid cooler and aftercooler is dissipated heat, whereas the heat recovered from the drive motor is radiated heat. Together, the heat recoverable from these three parts (theoretically) totals ninety-four percent of the electrical energy consumption.

The greatest percentage of heat that can be recovered in the fluid cooler is seventy-two percent of the electrical energy consumption. The total heat recoverable from the drive motor and compressed air aftercooler is nine and thirteen percent respectively. The six percent of heat lost comes from the heat radiated from the compressor (two percent) and heat remaining in the in the compressed air (four percent). Being able to recover the ninety-four percent of heat largely depends on the options available in your industrial air compressor.

Redirection of heat can be achieved by using conventional HVAC ductwork and controls. This allows warm air from compressors to either provide or remove heat in the compressor room or adjacent areas. Practical applications of the redirection of heat can be used as auxiliary or primary heating for warehouses and workshops, drying air for paint spraying or washing, air curtains, and improving oil burner efficiency.

Space heating, PTG water heating systems and SWT water heating systems can all be used to redirect heat. If your space heating has a ducting system, it can redirect the heat made by the air compressor. The air compressor makes heat which then flows through the vents and is redirected throughout the facility.

A PTG water heating system is composed of a compressor, plate-type heat exchanger and hot water storage tank. The plate surface allows for heat exchange, created through turbulence, and is ideal for hot water supply plants where mixing water and cooling fluids should be avoided. It automatically directs the flow of water through the standard fluid cooler if minimal hot water is needed.

A SWT water heating system is made of tubes with a heat transfer medium fitted between adjacent tubes. An expansion tank maintains the pressure of the heat transfer medium; the pressure system is controlled by a pressure switch, which can shut down the compressor in the event of breakage or corrosion. This system ensures constant compressor cooling whether or not hot water is needed.

Kaeser Compressors has been in the manufacturing industry for over 90 years, producing the highest quality compressed air and blower products all around the world. Founded in 1919 by Carl Kaeser, the company has been manufacturing products designed for reliable performance, easy maintenance and maximum energy efficiency. With a large variety of compressed air and blower products, customers, be it individuals, small businesses or large companies, can choose and enjoy the luxury and the highest quality standards of all Kaeser products.

An example of their quality products is the Kaeser compressed air filter. These compressed air filters are a perfect match to compressor and compressed air treatment equipment. These filters operate efficiently even under low use conditions.

Compressed air filters have various components to ensure that they work reliably and efficiently. The device has a filter change maintenance indicator which indicates when the filter needs to be changed. However, this indicator is optional. The filter element itself is high performance, so that there is reliable filtration going on without much pressure loss. A shut-off valve allows maintenance of the condensate drain without interfering with the air supply. The filter housing is durable, anti-corrosive and has an epoxy resin coating both inside and out. The Kaeser filters also have an audible warning if leakage ever occurs. Because of these high quality components, your filter is guaranteed a long service life.

It is very important to properly select and use compressed air filters because these filters will help keep you compressed air equipment in good condition. They will help prevent both short term and long term problems with your equipment thus saving money by avoiding excess and unnecessary repairs, replacements, and maintenance.

The benefit of compressed air filters is that they properly clean the ambient air, which contains millions of particles that enter the compressor. This includes dirt and other harmful particles, even bacteria and viruses as well as hydrocarbons. It is very possible that these particles will still be present even in the resulting compressed air if not filtered. This can damage the integrity of the equipment and other components such as air tools.

Careful treatment of the air is very important because clean, quality compressed air maximizes equipment life, ensures pneumatic machinery components are performing at their peak, and prevents contaminant build-up in pipes and valves.. Overall, the use of compressed air filters reduces service, maintenance and repair costs.

Proper maintenance of your industrial air compressor should always be a top priority, as it will not only keep your expensive machine working in top shape, but also keep repair and maintenance costs down. One of the most important aspects of air compressor maintenance is condensate management, which is the removal of condensates from the air compressor system.

Oil and water separates are a common tool used to filter out excess and unwanted oil and water vapor from the air compressor system. These separators are installed directly into the air compressor system to remove the excess oil and water as the process of compressing air is undertaken. Once the oil and water have been separated from the air, the oil levels must be reduced to legal limits or else serious fines and other penalties could arise. Most separators have a built in system to reduce oil to safe levels, but always be sure to check with your local municipality to be sure that you are in legal compliance with disposing of this waste. One of the ways you can be sure that you are always in the legal range when it comes to waste disposal is to periodically send out samples of the reduced oil for testing and analysis.

The old system of removing the collected condensates from the air compressor site was to use a waste management company, but rising costs have forced industrial air compressor users to look for alternatives. There are many different types of air condensate management systems that can be used independently within a company, and can separate almost any compressor fluid from the condensate. By having this automatic separation, it is possible to remove all the water vapor moisture from the air and dispose of it on site, while taking the remaining oil contaminants and recycling them for later use or disposing of them in a safe, cost effective manner.

These essential steps and components will keep your industrial air compressor running at its optimal level. Cleaning and removing condensates from your air compressor, such as oils, waters, organics like bacteria, dust, and even gases such as carbon dioxide will keep repair costs for your large system down. Clean compressed air will not only allow you to use your industrial air compressor over and over again, but it will also protect the environment from being exposed to harmful airborne contaminants and vapors. So always be sure to use preventative maintenance when it comes to your industrial air compressor system, especially when it comes to removing and managing condensates.