Category: Compressed Air Optimization

What Is a Centrifugal Air Compressor? How It Works and Why It’s Used in Industry

Published on by Tyler DanielLeave a comment

One thing that’s found in nearly every industrial environment is an air compressor. Compressed air is used to power tools, operate packaging and automation systems, run conveyors, control valves, and more. Pneumatic tools remain popular because they’re smaller and lighter than their electric counterparts, offer infinitely variable speed and torque, and can often be safer than electrical devices in harsh or wet environments.

To power these systems, compressed air must first be generated, and that starts with the air compressor. There are two main categories of air compressors: positive displacement and dynamic. Positive displacement compressors trap a given quantity of air in a chamber, then mechanically reduce the volume to increase the pressure. Dynamic compressors raise air pressure by accelerating continuously flowing air with a high-speed impeller. The velocity energy of the air is then converted into pressure energy.

One of the most common dynamic types used in industrial applications is the centrifugal air compressor. In a centrifugal compressor, air enters the center of a high-speed rotating impeller, which can spin at more than 50,000 RPM. The impeller’s blades fling the air outward by centrifugal force, increasing its velocity and pressure. The kinetic energy of the moving air is then converted into additional pressure as it slows down in a diffuser. Centrifugal compressors are generally used where large volumes of air are required. They can handle flows from a few hundred CFM up to 100,000 CFM or more, with most plant installations falling in the 1,000–5,000 CFM range.

According to the Compressed Air Challenge, some of the key benefits of centrifugal air compressors include their ability to deliver oil-free, contaminant-free air, and the fact that they are often supplied as complete packaged systems up to 1,000 HP. They scale well, as the cost per CFM improves as size increases, do not require special foundation requirements, and are ideal for high-volume air delivery.

Of course, there are trade-offs to consider. Centrifugal compressors have limited capacity control options, reduced efficiency at partial load, and their high rotational speeds require precision bearings and specialized maintenance. They also tend to have a higher initial purchase cost compared to smaller positive-displacement units. Despite these considerations, centrifugal air compressors remain a reliable choice for facilities that require large, continuous volumes of clean, oil-free air.

Once your facility’s air is generated, the next step is making sure it’s used efficiently. Compressed air is one of the most expensive utilities in a plant, and any wasted air means wasted energy. That’s where EXAIR’s line of engineered Air Nozzles, Safety Air Guns, Super Air Knives, and Optimization products come into play, helping you get the most from every SCFM your compressor produces. If you’re looking to improve your system’s efficiency or solve a specific application issue, contact one of our Application Engineers. We’ll help you get the most out of your compressed air system from the compressor room to the point of use.

Tyler Daniel

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Image courtesy of the Compressed Air Challenge

Week 4 Back to Basics— Shut It Down When It Isn’t Needed

Published on by Brian FarnoLeave a comment

Well, trusty blog readers, we are now two-thirds of the way through the Six Steps to Optimizing Your Compressed Air System.

So far, we’ve:

The next step is simple but powerful: turn off compressed air applications when they’re not needed.

If your process doesn’t require compressed air continuously, the EXAIR Electronic Flow Control (EFC) can help. This device uses a sensor to automatically control how long your compressed air operation runs, turning it on only when needed.

A great example is from a customer who used compressed air to clean computer monitors. When the screen wasn’t in the airstream, the air was simply wasted. With the EFC, air was shut off automatically whenever it wasn’t needed—saving energy, reducing costs, and extending the life of equipment.

The objective in this step is crystal clear: when your compressed air doesn’t need to be on, turn it off and save.

For more information on the EFC—or on any part of our Six Steps to Optimizing Your Compressed Air System—feel free to contact us.

Until next week, keep optimizing.

Brian Farno, MBA – CCASS
National Business Development Manager

BrianFarno@EXAIR.com
@EXAIR_BF

Week 3 Back to Basics – Replace Inefficient Blowoffs

Published on by Brian FarnoLeave a comment

In the last post of this series, we talked about finding and fixing leaks in your compressed air system. Many readers found that step especially valuable—leak detection alone can uncover major savings opportunities. Now, it’s time to move on to step three in the Six Steps to Optimizing Your Compressed Air System: implementing engineered solutions.

Engineered solutions (like EXAIR Intelligent Compressed Air Products) are the efficient, quiet, and safe choice.

This is where our Application Engineers can really help. Whether your application calls for Air Knives, Super Air Nozzles, or another one of our engineered products, we can guide you to the right solution. If you already know the consumption rates of your existing setup, we can even help you calculate the savings you’ll see by switching.

Step three is often where customers begin to notice the biggest impact. Replacing an open pipe or a non-engineered blowoff with an engineered solution can drastically reduce compressed air usage. The difference becomes obvious when your compressor cycles less frequently—or in some cases, when you’re able to shut down a secondary compressor altogether.

In the next post of this series, we’ll cover step four: an even simpler way to extend your savings by turning air off when it isn’t needed. Until then, keep working toward a more efficient compressed air system.

Brian Farno, MBA – CCASS
National Business Development Manager

BrianFarno@EXAIR.com
@EXAIR_BF

The Hidden Costs of Inferior Compressed Air Products

Published on by Tyler DanielLeave a comment

Compressed air is one of the most versatile utilities in industry. It’s used for everything from part drying and debris removal to cooling and conveying. But not all compressed air products are created equal. Too often, I come across shops and plants relying on drilled pipes, open tubes, or cheap plastic nozzles to get the job done. On the surface, these might seem like quick and inexpensive fixes. In reality, they end up costing much more in wasted energy, unnecessary noise, and lost productivity.

Let’s start with drilled pipes and open-ended blow offs, since they’re some of the most common culprits. At first glance, they look like an easy solution. Just drill a few holes, hook up compressed air, and let it blast away. The problem is they waste a tremendous amount of air. They’re also extremely loud, often well above OSHA’s permissible noise levels outlined in 1910.95(a). In many cases, the sound exposure can reach levels that require hearing protection just to operate nearby. Beyond that, drilled holes create a dead-end pressure condition that violates OSHA 1910.242(b), which states that compressed air used for cleaning must be regulated to 30 PSIG if dead-ended. This is a serious safety concern that’s often overlooked until an injury or compliance audit brings it to light (or even worse, an OSHA inspection).

These wasteful and loud modular plastic tube blow offs…

Cheap nozzles and modular coolant hoses being used for compressed air fall into the same trap. They’re not designed to handle the pressures and flows involved in compressed air applications. This means poor performance, higher operating costs, and, in many cases, premature failure. It’s not unusual to see these hoses break down or simply pop off, creating unsafe conditions on the floor. What seemed like a cost-saving shortcut turns into downtime, frustration, and more expense down the road. The high consumption of these devices also leads to pressure drops elsewhere in your compressed air system.

This is where engineered solutions from EXAIR make the difference. Every nozzle, air knife, and air gun is designed with efficiency and safety at the forefront. Engineered nozzles, for example, reduce compressed air consumption while maintaining or even amplifying force. They also dramatically reduce noise levels, often bringing them into full OSHA compliance. Products like the Super Air Knife provide uniform airflow across an entire length while using a fraction of the air compared to drilled pipes.

In a previous blog, we shared an example where a customer was using a ¾” drilled pipe for blowoff on their production line. By replacing it with a 12” Super Air Knife, they reduced their compressed air consumption by over 80 SCFM. At their energy rate, this translated into more than $5,000 in annual savings, with a payback period of just a few months. Not only did they cut their energy bill, but they also eliminated an OSHA noise hazard and brought their system into compliance with dead-end pressure regulations.

When you factor in the rising costs of energy, the difference is not small. Inefficient or inferior products consume more compressed air than necessary, which means compressors work harder, energy bills rise, and maintenance intervals shorten. On the other hand, using an engineered solution is an investment that pays itself back quickly, often in months (or days) rather than years.

With engineered EXAIR products, you’ll improve efficiency, cut costs, reduce noise, and create a safer workplace. The short-term convenience of “cheap and easy” rarely holds up against the long-term benefits of doing it right the first time.

Tyler Daniel, CCASS

Application Engineer/Intl Trade

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD