What’s The Big Deal About Clean Air?

Compressed air isn’t called manufacturing’s “Fourth Utility” (the first three being electricity, water, and natural gas) for nothing. Pneumatic tools are popular because they’re often so much lighter than their electric counterparts. Compressed air can be stored in receiver tanks for use when other power supplies are unavailable or not feasible. Many compressed air operated products can be made to withstand environmental factors (high/low temperature, corrosive elements, atmospheric dust, oil, other contaminants, etc.,) that would make electric devices very expensive, unwieldy, or impractical.

One of the most valuable considerations, though, is that your compressed air system is, by and large, under your control.  The type and capacity of your air compressor can be determined by your specific operational needs.  The header pressure in your supply lines is based on the applications that your air-operated devices are used for.  And the performance & lifespan of every single component in your compressed air system is determined by the care you take in maintaining it.

I covered the importance of compressed air system maintenance in a blog a while back…today, I want to focus on clean air.  And, like the title (hopefully) makes you think, it’s a REALLY big deal.  Consider the effects of the following:

Debris: solid particulates can enter your air system through the compressor intake, during maintenance, or if lines are undone and remade.  If you have moisture in your air (more on that in a minute,) that can promote corrosion inside your pipes, and rust can flake off in there.  Almost all of your air operated products have moving parts, tight passages, or both…debris is just plain bad for them.  And if you use air for blow off (cleaning, drying, etc.,) keep in mind that anything in your compressed air system will almost certainly get on your product.

Your compressed air system may be equipped with a main filter at the compressor discharge.  This is fine, but since there is indeed potential for downstream ingress (as mentioned above,) point-of-use filtration is good engineering practice.  EXAIR recommends particulate filtration to 5 microns for most of our products.

Water: moisture is almost always a product of condensation, but it can also be introduced through faulty maintenance, or by failure of the compressor’s drying or cooling systems.  Any way it happens, it’s also easy to combat with point-of-use filtration.

EXAIR includes an Automatic Drain Filter Separator in our product kits to address both of these concerns.  A particulate filter element traps solids, and a centrifugal element “spins” any moisture out, collecting it in the bowl, which is periodically drained (automatically, as the name implies) by a float.

Point of use filtration is key to the performance of your compressed air products, and their effectiveness. Regardless of your application, EXAIR has Filter Separators to meet most any need.

Oil: many pneumatic tools require oil for proper operation, so, instead of removing it, there’s going to be a dedicated lubricator, putting oil in the air on purpose.  Optimally, this will be as close to the tool as possible, because not all of your compressed air loads need oil…especially your blow offs.  If, however, a blow off device is installed downstream of a lubricator (perhaps due to convenience or necessity,) you’ll want to do something about that oil. Remember, anything in your system will get blown onto your product.

If this is the case, or you just want to have the cleanest air possible (keep in mind there is no downside to that,) consider an EXAIR Oil Removal Filter.  They come in a range of capacities, up to 310 SCFM (8,773 SLPM,) and the coalescing element also offers additional particulate filtration to 0.03 microns.

In closing, here’s a video that shows you, up close and personal, the difference that proper filtration can make:

If you’d like to discuss or debate (spoiler alert: I’ll win) the importance of clean air, and how EXAIR can help, give me a call.

Russ Bowman
Application Engineer
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Oil Removal Filters – Keeping Compressed Air Clean

Compressed air filters help to keep the air clean and condensate free to protect equipment from dust, dirt, pipe scale, oil and water. Even though the compressed air system will typically have a main dryer, additional treatment is often necessary. For this discussion, we will focus on the oil removal process and filter type.

After the compressed air has passed through a particulate filter, the dirt, dust and water droplets have been removed.  Oil that is present is much smaller in size, and mostly passes though the particulate filter.  The installation of a coalescing filter will provide for the removal of the majority of the fine oil aerosols that remain. The coalescing filter works differently than the particulate filters. The compressed air flows from inside to outside through the coalescing filter media. The term ‘coalesce’ means to ‘come together’ or ‘form one mass.’  The process of coalescing filtration is a continuous process where the small aerosols of oil come in contact with fibers of the filter media. As other aerosols are collected, they will join up and ‘come together’ and grow to become an oil droplet, on the downstream or outside surface of the media.  Gravity will then cause the droplet to drain away and fall off the filter element.

9005
Example of a 0.03 Micron Coalescing Oil Removal Filter

Some important information to keep in mind –

  • Change the filter regularly, not just when the differential pressures exceeds recommended limits, typically 5 PSI
  • Coalescing filters will remove solids too, at a higher capture rate due to the fine level of filtration, using a pre-filter for solids will extend the life
  • Oil free compressors do not provide oil free air, as the atmospheric air drawn in for compression contains oil vapors that will cool and condense in the compressed air system.

If you would like to talk about oil removal filters or any of the EXAIR Intelligent Compressed Air® Products, feel free to contact EXAIR and myself or one of our Application Engineers can help you determine the best solution.

Brian Bergmann
Application Engineer

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