Air compressors are indispensable in various industries, providing the power needed for a wide range of applications. However, one common issue that can significantly impact the efficiency and longevity of these systems is moisture. The presence of moisture in compressed air can lead to equipment damage, product contamination, and operational inefficiencies.
Air compressor moisture problems arise when water vapor condenses within the compressed air system. This condensation is a natural byproduct of the air compression process. As air is compressed, its temperature increases, allowing it to hold more moisture.
When this air cools, the moisture condenses, leading to water accumulation in the system. This moisture can cause various issues, including corrosion, rust, and contamination of end products.
Several factors contribute to the presence of moisture in compressed air systems:
- External Factors: Ambient temperature and humidity levels play a significant role in the amount of moisture that enters the system. Higher humidity levels result in more water vapor being compressed.
- Compression Process: The act of compressing air increases its temperature, allowing it to hold more moisture. As the air cools, this moisture condenses.
- System Design: The design and size of the compressor, as well as the required pressure, can influence the amount of moisture produced.
Condensation is a natural result of air compression. The amount of water produced is dependent on the air inlet, quality of the surrounding air, and pressure. Warm humid air has a higher water volume than cold air. This will lead to more condensation. For instance, a 55 kW screw compressor, operating at a surrounding temperature of 24°C, with 75% air humidity will produce up to 280 litres a day.
Moisture in compressed air systems can have several detrimental effects:
- Corrosion of pipes and working elements
- Damage to pneumatic controls, resulting in machine failure
- Oxidation and wear and tear because lubricants get washed away
- Discolouring, lower quality and lacquer damage
- Freezing (in colder circumstances)
- Higher maintenance costs and shortening of machine lifespan.
In the following part we will briefly discuss the different types of air dryers, and why they might be the ideal choice for your system.
Non-cycling refrigerated air dryers
This is an ideal budget choice to ensure dry air. Non-cycling means that this air dryer operates constantly: it uses a hot gas bypass valve to redirect the refrigerant. It has a low cost of investment, they are easy to install and operate, and are ideal in combination with rotary screw compressors. For piston compressors we recommend a higher temperature model. Since this type of dryer operates constantly, this is not the best option in terms of energy efficiency.
Cycling refrigerated air dryers
As opposed to non-cycling dryers, these dryers have additional equipment to detect the amount of compressed air in your system. This means they will turn on and off based on the demand. Cycling dryers are therefore a more energy-efficient solution. The initial cost is higher, but it is definitely a more long-lasting option. Does your system have a fluctuating air demand? Then this is the choice for you.
These types of air dryers are inherent to your system. This is an advantage when you have limited space, and want to cut back on installation costs. We can definitely help you choosing an integrated dryer suited to your needs.
While refrigerated air dryers use a refrigerant to remove moisture, desiccant air dryers use heat, chemicals or drying materials. You’ll find more information on desiccant air dryers in our guide on compressed air dryer types. Overall, we can tell you that the choice for refrigerated or desiccant air dryers depends on the air quality requirements. We will be happy to answer any questions you might have.
Proper disposal of condensate is necessary to comply with environmental regulations and avoid fines. Condensate often contains oil and other contaminants, so it must be treated before disposal. Drainage setups, including automatic, timer, or electronic drains, should be installed to dispose of condensate properly.
What causes air compressor moisture problems?
Air compressor moisture problems are caused by external factors such as ambient temperature and humidity, as well as the compression process itself, which introduces water vapor into the system.
How can air compressor moisture be prevented?
Moisture can be prevented by installing dryers, aftercoolers, and drains to remove moisture and impurities from compressed air and meet air quality standards.
What types of drying equipment are commonly used?
Refrigerant dryers and desiccant dryers are commonly used to remove moisture from compressed air. Refrigerant dryers cool the air to remove moisture, while desiccant dryers use adsorbent materials to attract water vapor.
Why is proper disposal of condensate important?
Proper disposal of condensate is necessary to comply with environmental regulations. Condensate often contains oil and other contaminants, so it must be treated before disposal.
Trust your air compressor maintenance to an expert
Everything mentioned in this article, is a simplified version of things to keep in mind when servicing your air compressor installation. Never perform any work on your screw compressor, piston compressor, air treatment or other equipment that you are not qualified to perform, but instead consult an expert.
Specialised air compressor experts know your system inside and out and are licensed to handle any situation, no matter what issue arises. Moreover, they’ll be able to provide pointers on how to better use your compressor.
Maintaining your air compressor is far more sustainable than buying a new one every few years, so make sure you take the time to really keep it up. If you’re looking to save money, refrain from buying a second hand compressor, and focus on quality parts and preventative maintenance.
Looking for some assistance? Get in touch with our experts for services that meet your needs.
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