Moisture, particle contaminants, microorganisms, and gases are present in the atmospheric air. The concentration of such particles increases by 6-10 times when this air is compressed. As atmospheric air is compressed by a compressor, other contaminants like oil and traces of metal are added. Because of this, it is important to remove these contaminants from compressed air before using it. We are the leading Moisture Separator Manufacturer in India.
Contaminants can be categorized as follows:
- The particles
- Water (liquid, vapor, aerosol)
- Liquid, vapor, and aerosol oil
- The microorganisms
- Gases other than oxygen
In accordance with ISO 8573-1:2010, compressed air contaminants like particles, water, and oil are classified according to purity classes. There is no mention of microorganisms or other gases in this standard. In this way, air purity is indicated as [P, W, O] and is ordered based on the particle, water, and oil content.
Depending on the application, downstream equipment is required to remove contaminants from compressed air.
It is possible, for example, to remove particles, water, and oil contaminants from compressed air by using downstream filters. For removing water from compressed air, bulk moisture separators are recommended.
Because the moisture separator usually uses after the cooler, it is necessary to have a proper automatic drain along with it. To prevent bulk water from contaminating downstream equipment, condensate must remove optimally. If you want to get this done with the least amount of air loss, it recommends that you use a level-sensing zero-loss drain in combination with a moisture separator.
There are various configurations and types of downstream filters. In terms of residual oil and particles after filtration, these can divide into the following groups:
To remove water and oil aerosols from compres air, coalescing filters recommend. Following filtration, coalescing filters can be classified based on residual oil and particle content. In general, coalescing filters can divide into two types: With the first type,
By using a pre-filter, particles and oil can be purified to class 3 or 2, according to ISO 8573-1:2010 [2:2-1:2]
Installation should be perform in the following order: bulk moisture separator, prefilter, bulk moisture separator
It is possible to achieve class 2 or 1 purity of oil and particles using the fine filter, according to [1: -:2] ISO 8573-1:2010
Installing bulk moisture separators, prefilters, dryers, and fine filters in that order recommend In compress air, the particulate filter removes dry particles and microorganisms. A desiccant dryer uses this filter to ensure that desiccant particles do not carrie to compress lines.
Purity classes made possible by this filter are 3,4,5 and 6, which define in ISO 8573-1:2010 in the following manner: 3: -: –
Install the bulk moisture separator, pre-filter, desiccant dryer, then the particulate filter in this order: bulk moisture separator, pre-filter, desiccant dryer, and particulate filter.
Coalescing filters are not effective at removing oil vapor from compress air, so carbon filters recommend instead.
A carbon filter can achieve purity class ”1”, which corresponds with the ISO 8573-1:2010 [-:-:1] specification.
Ideally, pre-filters, dryers, fine filters, and then carbon filters should follow carbon filters
The right filter selection and ensuring their optimal performance requires consideration of the following factors
Base 7bar operating pressure (nominal condition), the filter capacity calculate. It is important to use the correction factor if the operating pressure is different and select the filter model accordingly.
During the installation of filters, it is important to follow the correct sequence to achieve optimal performance. Filtration levels should be in sequence, ranging from 20 ppm to 5 microns or from 10 microns to 1 micron to 0.01 microns.
After the 0.01 micron filter, carbon filters should always follow. Unless this sequence follows, it will choke up faster and have a shorter lifespan.
A proper drain recommends along with the pre-filter since the pre-filter usually use before the dryer. Condensate should remove regularly to prevent moisture from infiltrating downstream equipment.
It is important to replace the filter element at the recommended service interval. There is an indicator of saturation level on the filters, and if it appears, the filter element should replace. The purity class required will not achieve a saturated filter element. Consequently, the compressor will have to work harder to compensate for the higher pressure drop. Compressors will have a 1% increase in load for every 0.14bar/2psi pressure drop. It is important to replace carbon filters regularly as they function by adsorption.
Compressors and downstream equipment collect the oil-emulsified condensate. After, the condensate must treat for oil removal before being discharge into the sewer
Eventually, the water will evaporate from the oil-emulsified condensate, leaving the oil behind.
To remove the oil from oil-emulsify condensate before it discharges into a sewer, it is necessary to select an oil-water separator:
It is important to select the right oil water separator and element to remove oil from condensate within the region’s permissible limits. In ppm units, this expression.
Ensure that the oil water separator selected is compatible with the compressed air and condensate mixture flowing through the condensate line. Monitoring the PPM level after separation is crucial. PPM levels above recommend level indicate the element needs to replace. A life indicator for elements is also available on some oil-water separators to make identification easier
To remove contaminants from compressed air, follow these best practices:
Choosing the right size moisture separator to remove maximum bulk moisture from the system, preventing it from being carr downstream
A coalescing filter must be select base on its type, rating, size, and the appropriate preceding level. It is important to replace the filter element at the appropriate intervals.
Condensate remove from compressors and downstream equipment with the help of electronic drains. It is crucial to maintain and replace an electronic drain regularly, as recommended.
So that compress air is free of water vapor, dryers must use fine filters and carbon filters. Having the vapor pass through the filter element is critical, as it can choke it.
Before fine and carbon filters, particulate filters recommend after desiccant dryers
If a small area of the application requires more stringent air quality, an additional dryer and filter set should install nearby. These dryers usually have a lower dew point because they are membrane or desiccant types.
Maintain the pipelines for compressed air and check for leaks. Compress airlines can contaminate outside contaminants when there is a leak. When the compressor stoppe (when there is no positive pressure inside the pipe), these leaks allow outside air to creep into the piping. Water leaks cause the pipe to rust and carry other impurities inside, which, when the compressor restarts, may be care forward.
Airmax Pneumatic is the leading Moisture Separator Manufacturer in India. We offer various types of industrial pneumatic valves and cylinders.
Also, read “All You Need to Know About Pneumatic Valves“
