Top Tip: Buying Guide for Energy Efficient Air Compressors

Air is the most important thing about an industrial air compressor, meaning the air that goes into the compressor and compressor air that goes from the compressor to your industrial application. For the compressed air to meet ISO 8573-1 air quality standard, the air that does into the process should be as clean as possible and free of any smoke or dust particles. If your industrial plant is situated at a location where the dust concentration in the atmosphere is high, you can use a pre-filter. 

The choice of an oil-injected or oil-free air compressor depends on the air quality required for your applications. Similarly, the required pressure and flow rate of compressed air for plant equipment determine the optimal size of the air compressor you should buy, In the same way, compressed air usage pattern and air consumption of the end machine determines whether you need a fixed or variable speed industrial air compressor. All these things need to be catered accordingly by choosing an appropriate energy-efficient air compressor.

The distance between the air compressor to the end machine should be kept at minimal for energy-saving purposes. It is advised that the air compressor should be placed in the central region of the plant to transfer compressed air easily to all industrial equipment. This way you can save from any unwanted pressure losses during the compressed air transfer, making your business cost-efficient. Energy audits and walk-the-line compressed air assessment tests can also help to analyse the energy efficiency and optimal distance of your air compressor from the industrial equipment.

The compressor room is a closed confined space within the facility with air compressors placed inside. You should consider the features of the compressor room when buying an air compressor. To protect your industrial air compressor from wear and tear due to undesirable weather conditions, a compressor room with ideal characteristics is suitable. The compressor room should include an efficient ventilation system to help dissipate heat energy. 

You can also invest an energy recovery system and use this heat in other applications. The compressor room must be designed so air coming into the room and then to the compressor is as clean as possible. The volume of atmospheric air coming inside the compressor room should be enough to limit temperature rises till 7-10°C with a maximum air velocity of 4 m/s. An ideal location for your compressor room would help in improving the operating economy of your air compressor by decreasing the working pressure fluctuations.

It is important to also devote enough time to figure out the optimal distribution system for your air compressor before purchasing it. An ideal piping system would prevent pressure losses by maintaining the compressed air flow and minimising throttling effects across your facility. For starters, draw a diagram of the distribution network of compressed air. A closed-loop pipeline system with a network of risers, distribution pipes and service pipes would be ideal. 

The consumption points within your facility should be grouped in logical units and the supplied by compressed air accordingly to maximise efficiency. Besides, the length and diameter of the pipes should be properly calculated to minimise friction and pressure losses.

The compressor's intake air must be clean and free of solid and gaseous contamination. Particles of dirt that cause wear and corrosive gases can be particularly damaging. A pre-filter should be used in installations where the surrounding air has a high dust concentration. In such cases, the pressure drop caused by the pre-filter must be accounted for during design. 

It is also beneficial for the intake air to be cool. Therefore, it may be appropriate to route this air through a separate pipe from the outside of the building into the compressor. All our compressors include a 3 microm inlet filter to protect the internal elements.

It is often critical for several installations to remain operational at higher and lower temperatures. So, what kind of compressed air installation is the best fit for your plant? What effect does the ambient temperature have on your compressor and compressed air installation? 

When the compressor draws in ambient air at a significantly higher ambient temperature, the installation has to work harder (i.e. more rotations/loaded hours) to produce the same quantity in Nm³. 

Think of it as a balloon that you have inflated. Leave it in the sun and it will expand. leave it in a refrigerator and it will shrink. To produce the same volume, you would have to inflate more balloons in the sun.