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.

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.

When it comes to powering pneumatic tools, factory equipment, or heavy machinery, compressed air is one of the best sources of energy. In order to utilize the power of compressed air in a large, industrial setting, you are going to need an industrial size air compressor. While there are many standard types of industrial air compressor available, getting a custom made one might end up being the best option for you.

There are two main types of industrial air compressors: positive air placement ones and dynamic type machine ones, in which they automatically increase air pressure, as well as elevating the air to a higher pressure. The types of industrial air compressor are further broken down into reciprocating, rotary screw, and rotary centrifugal systems.

Rotary air compressors use two rotors within a casting device which compresses the air internally in the system. These machines use a rotary system of positive expulsion to move pressurized air throughout the machine and into connecting hoses, where it is expelled at high pressures, providing compressed air energy. Rotary air compressors contain no valves in the system itself and are often oil cooled, so be sure to take the proper preventative maintenance steps when it comes to keeping your rotary air compressor running efficiently.

Another type of industrial air compressor you could use is the dynamic air compressor, which produces a high amount of air pressure from the conversion of angular momentum imported by a rotating impeller device. Again, always be sure to take the proper preventative maintenance steps when dealing with a dynamic air compressor, as it is important to check this impeller device on a regular basis to make sure that it is still functioning at its normal, high efficiency capacity. One of the advantages of a dynamic air compressor is that it allows for a high capacity of air to run through the system because the flow through the compression chain, and the entire system itself, is continual. These industrial air compressors are built oil free and therefore make them easier to maintain then their oil cooled counterparts.

These are just a few of the different types of industrial air compressors available on the market. A customized one will allow you to mix and match what you want in an air compressor, such as what expulsion system, what drying system, what cooling system, and so on. Be sure to research the product you are looking into from a reputable, established industrial air compressor dealer.