Where is an Air Compressor Used?
From airbrushing cars to making fertilizer
The air compressor is one of the most useful devices in our lives. It is used in small instruments like an airbrush, a medium-sized appliance like an air conditioner or refrigerator or a large factory like a cement plant. There are five main categories for the use of an air compressor. These are to:
- Fill gas cylinders with clean air
- Provide air to an underwater diver
- Power pneumatic tools
- Fill tires with air
- Provide large volumes of air for industrial uses.
Air that is compressed will return to atmospheric pressure once it is released. This makes compressed air a source of energy. This energy (and the air compressor that delivers it) is measured in terms of both the volume of air and the pressure or force. The force of air is expressed in terms of “pounds per square inch” (PSI) while the volume of the air is measured as “cubic feet per minute” (CFM). Both measurements compose the specifications of an air compressor.
The volume or CFM tells you what size of air compressor is needed to perform a certain function. As a rule of thumb, one horsepower will give you 4 cubic feet of compressed air at 100 PSIG. Therefore, a 5 horsepower air compressor will deliver 20 CFM at 100 PSIG while a 200 horsepower compressor will supply almost 1,000 CFM at 100 PSIG. More volume will get the job done faster. Some tools and motors cannot operate without sufficient air volume. For instance, an impact wrench will require 24 CFM at 100 PSIG while an 8-inch circular saw will need 45 CFM at 100 PSIG.
Among the many uses of compressed air are in:
- Production line tools in assembly lines
- Maintenance operations in chemical plants
- Aircraft manufacturing
- Automobiles
- Soft drinks
- Cement factories
- Foundries
- Plastics manufacturing
- Construction projects
- Hospitals
- Power plants
- Sewage plants
- Painting
- Ski resorts.
The air compressor is part of our daily lives. You will need an air compressor if you want to go biking and also if you want to scuba dive. If you’re throwing a party and need balloons, an air compressor will come in handy. The air compressor drives the blow moulding machines that make your shampoo bottle and delivers the oxygen when you’re in hospital. And it also puts the fizz in your soda pop.
An air compressor can be manually-powered. Most units, however, run on electricity or natural gas. Natural gas is less expensive but it emits fumes which are not advisable in an enclosed area as in spray painting. In this situation, an electricity-powered air compressor is preferred.
The Air Filter in an Air Compressor
It keeps things clean and running smoothly
Because the product of an air compressor is air, the air filter plays a critical part in its operation. There are many substances that can get into an air compressor system such as dirt, dust and metal oxides which interfere with the machine itself as well as the pipes and tubes. These particles can clog openings, wear out seals and other components resulting in decreased air output.
Combining with contaminants that get into the air compressor, chemical gases can cause more damage. Some of these gases are: carbon dioxide, chlorine, sulphur and freon. During the compression process, water is produced which in turn can cause molds and fungi in the system. These microbes produce waste which can clog pipes and cause valves to jam.
A good air filter in an air compressor can prevent this and ensure that only clean, dry air is in the system. There are several types of compressed air filters based on several filtration systems such as direct interception of contaminants, inertial impaction and diffusional interception using the Brownian Motion of small particles.
A compression intake filter is the first line of protection and blocks contaminants before they can enter the compression chamber. Aside from removing 80% of particulates, it also blocks chemical contaminants. Compressor air/oil separators are a type of filter used in rotary screw air compressors. This type removes oil and water droplets from the air stream. It also removes large solids that can interfere with the air flow.
A coalescing filter removes oil and water particles in the air by blending them into droplets. The droplets are then removed from the compressed air stream. A particulate filter removes large contaminants like scales and metal oxides. The high temperature particulate filter performs the filtering function but with protection against high temperatures which might be a cause of fire. Usually the final stage in the filtration process, a vapor filter removes chemical vapors which manifest themselves in things like odors and flavors. It is placed as close as possible to the output of the air compressor.
In summary, the purpose of the air filter in an air compressor is to deliver not just air but clean air and ensure that the air compressor functions efficiently. By removing all the impurities that can interfere with the operations of an air compressor, the air filter protects the parts of the machine and prolongs its life.
Replacing Air Compressor Parts
Air compressors are durable and last a long time
The are not too many air compressor parts to tinker with. For a device which plays such an important role in our lives, the air compressor surprisingly has very few parts. Air compressor parts operate to force air into a chamber where it is compressed and then release it in spurts. It provides power supplied by electricity, a diesel or gasoline engine into kinetic energy to power anything from airbrushes to factories.
There are two basic types of air compressors: a positive displacement type and a negative displacement compressor. In positive displacement air compressors, air is fed into the chamber by pistons, rotary screws or vanes mounted on slotted rotors. In the negative displacement type of air compressor, a spinning impeller uses centrifugal force to accelerate and decelerate the air which is then pressurized.
An air compressor is either open, hermetically-sealed or semi-hermetically sealed. A hermetically-sealed air compressor has the motor and compressor in a one-piece welded unit, such as those used in air conditioners. It cannot be opened and once it breaks down, it needs to be replaced. However, in semi-hermetically sealed and open type air compressors, parts can be replaced when they are worn out.
Most important of air compressor parts is the pump. From ½ to 5 horsepower air compressors use single-stage pumps while those above 5 horsepower use two-stage pumps. A centrifugal pump is needed for a negative displacement type air compressor.
Another vital part of air compressor parts is the air tank. They come in different sizes and are either horizontal or vertical. Depending upon the size, the air tank may be stationary or portable. Portable air tanks can be made of heavy-duty or industrial grade steel. Some come provided with wheels for easy transport.
The third major component of air compressor parts is the power source. It can either be an electric motor, a gasoline or diesel engine. Electric motors can range from 1/3 to 15 horsepower depending upon the pump requirements.
The other air compressor parts consist of the air filter, manifolds, valves, regulators, switches, pressure gauges, fittings and controls. Other parts are accessories of the tank, pump and engine such as capacitors, belts and a starter. The simplicity of the air compressor design makes it a very durable machine. It requires little maintenance and replacement of air compressor parts does not happen very often.
