Air Compressor Basics
The Best Parts Of The Rotary Screw Compressor
Now, if you’ve been around compressors for at least a week, you will have heard of a rotary screw air compressor, you know, the one you have if you don’t have a reciprocating compressor. Both of these compressors are positive displacement compressors; the main difference between the compressors is their applications and the way the units are built. Rotary Screw Compressors do not use valves like the reciprocating compressors do to move the air downstream.These compressors have become an industry staple due to their reliability, noise level, and efficiency. Through the use of two motors, pressure is created to compress the air. The simplicity of their design makes these some of the easiest compressors to use and maintain. The standard enclosure features technology to reduce the noise of an air pump that is already much quieter than a reciprocating piston compressor. The way that the rotary screw compressor starts and stops uses less energy than the reciprocating piston would in the same environment.Now how did this machine come about? Is it a modern revelation or a cumulation of time and energy going into making a machine of that caliber? Well you may be surprised to know that the original patent for a “Screw Blower” #4121, was obtained on March 24th, 1878 by a German engineer named Heinrich Krigar. He would then go on to receive two more patents for his 2+2 helical compressor that was capable of making less than 2 psig. So this technology, although nowhere near as refined as it is now, was incredibly groundbreaking.These compressors have come a long way in 145 years from just under 2 PSIG to machines that are powerful enough to power an entire manufacturing facility. So just how far have these compressors come and how do they work now? How Does The Rotary Screw Compressor Work?The main components of these compressors are the male and female rotors. In order to create pressure, these two rotors turn in opposite directions. As the air is moved through the rotors, the space between the individual rotors, as well as the housing for them, is decreased to create compression. Each individual screw component has a built-in pressure ratio that is fixed based on the length and pitch of the screw as well as the shape of the discharge port. These fixed ratios are crucial to making sure the built in pressure ratio is properly adapted to the working pressure.Now that the more technical explanation is out of the way, let’s take a look at the step by step process of how rotary screw compressors create compressed air: Gas is sucked into the compression chamber, which consists of the two screw rotors. As they rotate, the air is isolated in the cavities and moved down the chamber through the rotors. The overall size of the chamber decreases as it moves away from the opening. This process decreases volume and increases the pressure. The pressure builds and the air is condensed. Once the pressure has reached the threshold, the discharge valve will open and move the air into the next step of the process, whether that be dryers, storage, or filtration. The process of compression is streamlined and requires less internal movement of the air in comparison to the reciprocating compressors. The air is pulled in and as it moves through the compression chamber pressure is applied to compress it. No matter the variation, this process remains the same across all rotary screw compressors. These aptly named compressors are known for their consistency and efficiency and they can come in oil lubricated or oil-free.https://youtu.be/qW2RANdPUJ8 Wait What Needs OilRotary Screw compressors are typically divided into two main technologies when it comes to their oil usage: Oil-free and Oil-injected. Both of these options cover all of the needs for rotary screw compressors. If there are high air quality standards, you might need an oil-free, but for everything else the oil-injected is going to work just fine. These two technologies are often referred to as dry and wet screws respectively.The main difference, besides oil content, is how the rotors spin: Oil-Lubricated Screws the male rotor drives the female rotor Oil-Free Screws a timing gear is responsible for ensuring a calculated clearance between the two rotors. Oil-Free Rotary Screw CompressorsThis variant of compressors comes with an asymmetric screw profile to boost energy efficiency and reduce internal leakage. These compressors rely on the timing gear to prevent any contact between the rotors. This results in high-speed compressors with unmatched efficiency that also delivers extremely clean air on demand; however, in order to reach this level of quality the attention to detail needs to be extreme.External gears are the key component for making sure that the screws are synchronized to prevent any unwanted contact between the two. By preventing contact between the rotors and the housing from occurring, there is no need for lubrication to be present on the rotors. This allows the byproduct to be completely oil-free. Without having any oil in the compression chamber, these machines are able to deliver air that is completely oil-free.These units typically work in several stages due to the built-in pressure ratios limiting the components. Through multiple stages and intercooling between them, these compressors can reach higher pressures while still not using oil to help cool the air internally. This helps to limit temperature differences between the air being brought in and the final product. Temperature is important to monitor in oil-free compressors due to the way they heat up rapidly.These compressors do not have the oil in the compression chamber to help reduce the temperature of the air back down to recommended limits. This creates a need that is not present in your standard oil-injected screw. It requires adequate lubrication on bearings and bearing surfaces to ensure reliable and efficient operation. Overall these machines come at the cost of needing more mindful maintenance, but the product these machines create is unlike any other compressed air.Oil-Injected Rotary Screw CompressorsCompletely opposite of the oil-free model, the oil injected/flooded/lubricated goes by many names for the same process. These machines use oil that has been injected into the compression chamber to lubricate the components, as the male rotor is responsible for driving the female rotor in these machines. Friction is impossible to avoid when one component is responsible for turning another and lubrication is needed to make sure that friction does not wear down the parts.With friction comes heat, and this heat needs to be removed from the air before it goes downstream and potentially causes problems with the equipment. By removing heat from the air stream, the amount of vapor present in the air stream is reduced and minimizes leak potential. Although more oil is being introduced into the compression chamber, the air and equipment benefit greatly from this being introduced.Even with the benefits of compression, it's important to ensure that as much oil has been removed from the air as possible. Compressors often have a centrifugal separator to help remove and reuse the oil. This method does not remove all of the oil, there will be some carry over downstream as the oil passes through in the air. This oil will be removed downstream by passing through filters and a dryer. The oil that's removed from the air is cooled down and recycled back into the chamber to continuously cool the air.Depending on the application, compressed air may undergo more or less filtration than others. This is ultimately determined by the air quality standards and specifications like temperature, CFM, and PSI can all create a difference in your performance. It is important to know what your individual application needs when it comes to determining the details of how your compressor operates. Rotary Compressors Can Run at Whatever Speed You Need With VSDsWhen it comes to rotary screw compressors, they have access to technology that no other compressor can compete with: The Variable Speed Drive (VSD). VSDs can go where no other compressor can, they can match the rate of production to your needs.When it comes down to it: Fixed Speed compressors run at one speed when they are running, they are either on or off Variable Speed Drives run at the speed necessary to fulfill the current demand. Why Would I Want a Fixed Speed?Fixed-Speed compressors when properly sized will deliver when they are needed. These machines run at 100% of their capacity or 0% and no in between. The problem here occurs when the machine is winding down and the motor is not producing air but is still rotating and using energy. This means precious time and money is being wasted whenever the machine is not running at full capacity. So if this machine isn’t as efficient as a VSD why would it be something you would want to invest in?The main differentiator between the two, aside from speed, is the initial cost. VSDs can be a lot more expensive upfront. Fixed Speed compressors can be a valuable asset to your operation if you need a continuous supply of air. IF you just need air consistently, the fixed-speed compressor will be the right fit for you. That being said, you will still be wasting valuable energy and money when the machine is not in use.https://youtu.be/RYMELetN5Ys Should I Use A VSD Rotary Screw Compressor?The VSD currently has a monopoly on energy efficiency. No compressor can compete with the energy savings that come with using a VSD. These compressors can save you anywhere from 35-60% of your total costs of ownership. Although the initial investment may be steeper than a fixed-speed rotary screw compressor, the Variable Speed Drive will end up paying for itself in no time.These machines are the unsung heroes of slow production days, slow second and third shifts, and understaffed periods. Changing operational speed to match need reduces the energy usage during slow periods. So in short, on slow days the VSD will save you more money than any other compressor would.Where Would I Use a Rotary Screw Compressor?With the rotary screw compressor, there are a multitude of different applications that it can be used for. From manufacturing to pharmaceuticals, these compressors can simply get the job done. They are built to handle whatever you throw at them.The Typical Applications for Rotary Screw Compressors: Food and Beverage Manufacturing Painting Automotive Agriculture Food Packaging Construction Energy HVAC Of course this list is not all inclusive of every possible application for a rotary screw compressor. This is in place to give you an idea about whether a screw is right for you. Before You BuyRather than delve into the details, let's go over the benefits to going with a rotary screw compressor. There are five main points we are going to focus on. Energy Efficiency Due to low heat emission and the potential use of a VSD, these machines are more energy efficient than their reciprocating piston counterparts. Long Lifespan A combination of easy maintenance and low heat emissions make this machine the ultimate workhorse. These machines can run full at full power 24/7 and still experience minimal capacity loss. Continuous Air Flow Plan and simple, there is no need for a cooldown period and that allows these machines to keep working and avoid overheating issues. The only time it would take a break is when there is no longer any capacity. Noise Volume With these motors not being in direct contact with each other, it creates a quieter environment around the compressor. Not only is the basic unit quieter, these machines can be made nearly silent with the right add ons. High Capacity Due to 24/7 compression, these compressors can make higher volumes of air than other models of compressors. Now all that’s left is for you to go get your own rotary screw compressor for your own application. These workhorses can be found from the best brands on our website. With access to the latest in VSD technology and compressor technology in general, you won’t be able to find a better machine. All it takes is a few clicks and you can be looking at the best fit machine for your application. Shop with us today. Learn More From Atlas Copco From The Compressed Air Blog From Mark Compressors
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An Easy Guide to Choosing an Air Compressor
Choosing the right compressor for your application is a pretty simple process, right? Well if you know anything about compressors you know that choosing an air compressor is not that simple. Finding the right compressor is an intensive process, there is no one size fits all answer, and I wish there was. You have to make sure your air has the right flow, the pressure isn’t too far off in either direction, you have the power to run the machine, and many other things that are integral to the process of making high-quality compressed air. Don’t let this overwhelm you when it comes to picking out your compressor, that is what this guide is for. Details Matter When Choosing an Air CompressorThe information needed to adequately size your air compressor is all important, but some things need to be addressed first. The most crucial ones to pay attention to are: CFM (Cubic Feet per Minute) Pressure (PSI/PSIG) Space By being able to identify the flow rate, pressure, space and air needs will lead you in the right direction of figuring out just what kind of machine you need. CFM is typically determined by the horsepower of the air end, so if you know your CFM you will have an idea of what horsepower you need to be running at and vice versa. Knowing these factors will greatly limit your options to make sure you are getting the best compressor for your application. After you know these things, you can focus a little more on the details of your compressor: Type of Compressor Technology Power Utilization Storage Noise Industry Air Standards These elements of choosing an air compressor come second not due to their importance, but instead are second as they do not help reduce your options, but instead are often extra variables that need to be considered before purchasing. Variables like storage, industry air standards, and noise can be corrected through additional components being added on to the compressor, however, others like utilization, technology, and the type of compressor need to be addressed prior to purchasing a compressor. Let’s Size a CompressorBy following along with this guide, you will be able to not only go through the process of picking your compressor yourself, but also know why those factors are important to consider. Outside of CFM, PSI, and Available Space, there is no particular order for these steps to be followed in and the variables can be determined however is easiest. The most important part is being able to identify and find the information you need. Lean on these variables when choosing an air compressor for yourself. CFM and Air FlowWhat exactly is CFM and the flow of compressed air? Well CFM is the volume of air that can be compressed by the pump in one minute: a high CFM rating means a compressor can provide more air, which indicates that the bigger your operation the more CFM you are going to need. With a preexisting system, it is pretty easy to identify your system’s output and how that air is being used. If a bunch of air being wasted, there may be a bigger problem than getting a lower powered air compressor.If you don’t have a pre existing system and are looking to make one, we can help you figure out what your expected CFM requirements would be. All this involves is taking inventory of your equipment, or expected equipment and note how much air is required for them to operate properly. Most hand held tools need between 30-40 CFM, while more industrial equipment can need 90-100 CFM to operate correctly. Once you have taken note of everything that needs compressed air, you should then figure out what CFM is required for operation. Get Those MeasurementsTo get those measurements you need to see what the tools are rated for, and then determine how long they are on a duty cycle. If it is only running a quarter of the time, 15 seconds of every minute it is running and if it is on a continuous cycle it is running every second of that minute so it would be using 4 times more air. Most tools are rated for the 25% duty cycle, so if you are going to be using the tool continuously, you will need to multiply the CFM by 4 to understand how much air you are actually using.Ensure that your tools are not cutting it close when it comes to having enough CFM. You want the ability to be variable based on needs and going a little larger than needed will give you that buffer. For all of your tools, take the CFM based on duty cycle and then add 50% of the total to it. For example, if your tools were rated for 5 CFM, you would want a compressor with a capacity for at least 7.5 CFM at your desired PSI. Pressure and HorsepowerWe’ve mentioned Pressure and PSI a few times now and these are the measurements for how much air is being compressed into a given space. It is a measurement of the air pressure delivered by your compressor. The higher the PSI gets, the more the air is compressed and with that increased pressure you can store more air in the tank. It is important to find the balance with your pressure so that you can maximize storage but still not waste energy and potentially damage your tools by having your air under excess pressure.If you don’t have a high maximum pressure, most compressors will work for you. For high pressure air you may consider looking into a two stage compressor where the air goes through the process of compression twice. The main point is to make sure that the PSI rating of your compressor is rated for at least your highest rated tool. This means if you have multiple tools and the highest is rated for 100 PSI, your compressor should have a pressure rating of at least 100 PSI.Horsepower is very similar to both CFM and Pressure. Horsepower is often tied to the CFM of a compressor. As it typically goes the higher the horsepower the higher the CFM, and the greater the pressure of that compressor the slower it will go. So a 10HP compressor that operates at 100 PSI will have a higher CFM than the same air end operating under 150 PSI. If horsepower is important to you, go ahead and use it as a measurement to find your compressor. If you already have a specific horsepower in mind it will greatly help limit your options. Available SpaceAlthough it may seem self explanatory, more goes into the placement of equipment than meets the eye. Choosing a compressor involves knowing your environment. Compressors need enough space to fit comfortably without sacrificing the quantity of air intake. Most compressors fit comfortably up against the wall, but it is important to look and see the type of space you have available. If you are lacking in space for a horizontal tank, vertical tank mounted compressors might work for you. Just because you have limited space does not mean you need to sacrifice storage or power.Being aware of the space that you have can be extremely beneficial to picking the right compressor. If you know you don’t have space for a horizontal tank you’ll need to look for a vertically mounted tank. Maybe you have the space but you need a dryer, you could do a full feature system with a dryer included that is mounted on a horizontal tank, or use that space for a vertically mounted unit with a dryer next to it. Point being, that if you know the space you have for the compressor it will be much easier to decide on the compressor you like and it can even impact the styles you are looking for. The Nitty Gritty of Your CompressorNow that you have a basic understanding of what you are looking for in a compressor, we can get into the details about what you really want when choosing an air compressor. Now if you are looking for a smaller personal use and don’t feel like this information applies to you, you already have all the information you need to find a good fit for you, but there may be a few things that sneak up on you. We still have not covered some variables that you may need to be on the lookout for.This is when you really get to decide the benefits of your machine. Little pieces and components you might not have noticed may end up saving you time and money in the long run. A lot of the components and pieces that may be considered additional can do wonders for your peace of mind and system longevity. Compressors aren’t a cheap investment so you should consider all of your options before you make a buying decision. So let’s go through the different options and variations you may want to consider. Choosing Your Type of Air CompressorChoosing an air compressor you need can be dependent upon a few things: the amount of utilization, duty cycle, quantity and quality of air needed. Each air end has strengths and weaknesses depending on the application. If you have a low duty cycle a reciprocating compressor would work for you but if you have a nearly continuous duty cycle you would want to go with a rotary screw compressor. This makes it hard to pick one based on how it compresses or the energy efficiency alone. Reciprocating PistonThe reciprocating piston compressor is the most commonly used compressor as it is the cheaper option in terms of compressors. They are an industry staple due to their longevity and broad applications. One of these machines can last anywhere from 15-20 years. These compressors operate in a manner identical to internal combustion engines- you know the ones that power most of our cars- except instead of the energy from combustion being pushed through, compressed air is the byproduct.As the crankshaft rotates the piston moves in and out of the compression cylinder. While the piston moves up, the air in the cylinder is compressed down and then moved onto stage 2. As the piston moves to its original position it pulls more air into the pocket for the next rotation. The air flow is directly determined by the size and speed of the pistons. Rotary ScrewThe rotary screw has become the go to for the auto industry and any industry that requires high quantities of compressed air for extended periods of time. With two intermeshing screws, consisting of one male and one female rotating screws. The air enters and is squeezed between these two helically opposed screws. As these screws rotate, the volume of space that the air is in is decreased and the byproduct of this is compressed air.These compressors are designed to run duty cycles of 80-100% and therefore are the favorites for manufacturers and auto shops that need consistent supplies of air to keep them going. They are typically a little more upfront but they make up for this in their energy-efficiency and long lifespan operating on long intervals.https://youtu.be/qW2RANdPUJ8 ScrollThe scroll compressor is the face of oil-free air. It operates in a similar manner to the rotary screw except rather than rotors it is a set of scrolls. One scroll is stagnant as the other rotates around in a circular motion to compress the air. The pocket of space shrinks until it is released at the desired pressure.As the moving scroll rotates around, it comes nearly into contact with the stagnant scroll but never quite touches it. This makes the rotary scroll the quietest and the cleanest of the bunch. These types of compressors are often used in places like dentists and doctor’s offices to power their tools with air clean enough to be used in a person’s mouth.If you are still unsure about what type of air end you would want, or are just wanting to learn more about the basics of compressed air before you buy, feel free to check out this post to learn more.https://youtu.be/b70ntv_95U8 Choosing Your Air Compressor TechnologyTechnology is the broad set of additional features or enhancements on the compressors. Anything from an upgraded control panel, to the motor operating at variable speeds to account for demand count as technology. These features are included on some of the newer models and series but not on the older ones. Make sure to compare the technology when choosing your air compressor. The big impact this will have on your compressor is up front costs and peace-of-mind later. Adding additional technologies will often increase the initial price of the compressor but it also will be the best version available on the market.These additional features can be beneficial in the long run but are also not completely necessary. If you don’t have a need for a Variable Speed Drive Rotary screw because you are only using 20 CFM at a 25% duty cycle. That type of investment would not make sense, but if you are in charge of an auto body and shop then you would consider making such an investment. The same thing can be said for all the other additional technology available: oil-free, upgraded display, energy efficiency, etc. Variable Speed DrivesEach one has its own perks and benefits to your system. They do come at a cost and you want to make sure you aren’t overpaying for your compressor. When it comes to deciding on additional technology make sure you compare the pros to the additional costs, it would be a shame to overpay for something that you do not need. The most common technology out there at the moment is the Variable Speed Drive or the VSD. This breakthrough in rotary screw technology lets the machine run at different rates depending on the demand.Most compressors are either on and running or off with no in between. VSDs have access to that in between so that less energy is being consumed to produce the air. During high demand the compressor runs at 100%, and once it diminishes the rate of compression will follow suit. This allows the compressor to fulfill demand without using as much energy as a fixed-speed rotary screw. It also minimizes energy spikes needed to get the compressor going. The initial investment is returned very quickly as these compressors can cut energy costs anywhere from 40-60%.https://youtu.be/JlNK27wyzTg PowerAn overlooked but incredibly important factor is the power source you have available for your compressor. A few potential thoughts come to mind when it comes to your power source: Is it single or three phase power? Does it run at a specific voltage? How many amps is your breaker rated for? Will you need to upgrade your power in order to get a compressor that fits your needs? Will you be using a power source other than electricity? These questions can help guide you through what you need to be thinking about when choosing your air compressor. Getting the power to line up is critical because if you don’t have enough power available the compressor won't run. Even the machines rated for single phase can attach a converter to make it work on three phase.Power is all about making sure you have enough to properly get your compressor running and keep it running. A simple check on how many amps you output and the type of power can go a long way with your compressor and making sure you get what you need.Now you may be wanting to move your compressor around or don’t have consistent electricity where you work and that is okay, there are diesel powered air compressors for those jobs. The same rules apply just with less information needed. If you use one of these you need enough fuel to keep the compressor running. (With the prices of everything though you would be better off going with electricity, if possible.) Utilization when Choosing an Air CompressorJust how often are you running your air compressor? Is it all day everyday? Do needs vary depending on time of day? These questions are all important to consider because utilization is the key to determining just what type of compressor you need. It is important to be aware of your individual usage so you can identify wasted energy.When it comes to utilization and choosing an air compressor, a simple rule to follow is: Less than 4 Hours a Day: Reciprocating Compressor Between 4 and 8 Hours a Day: Belt Driven Rotary Screw 8 hours and more a Day: Direct Drive Rotary Screw It wouldn't hurt to size up to give you that extra clearance just in case something were to happen. If you need a scroll for your application this information does not directly apply, this should be used to help determine whether a rotary screw or reciprocating piston will be more beneficial to your operation and your wallet. StorageCreating compressed air is very energy intensive and you want to make sure you have enough on standby. Standby Air will allow you to use your pneumatic tools free of worry. That backup air means even if your compressor goes down you will have air power for a little bit. The problem comes with trying to make sure you have enough backup air storage. A rule of thumb for storage is you should have 3-5 gallons for every CFM of air. If you are rated for 50 CFM you should have around 150-250 gallons of storage.Although storage is important, you can build a compressed air system that does not have one. However, it is not recommended to do so. Having that storage is your safety net and not having one is taking a risk that could otherwise be avoided. The tank is not responsible for making the air, it just means you have more time between duty cycles. You can never have too much storage but you can definitely not have enough. NoiseWhen most people think of a compressor they imagine a machine so loud you can’t hear yourself think. That is the reality of a piston compressor running at full load, but it doesn't have to be your reality. Most compressors come standard with vibration pads to help reduce the noise of the machine. Now you may be in a dentist’s office or using your compressor indoors and have it nearby. If this is you, there are plenty of options you can choose to limit that noise.Scrolls are without a doubt the quietest model you can go with. They are both oil-less and make no contact internally to avoid the process of making noise during compression. These compressors are also equipped with the technology needed to reduce noise even more. Quieter compressors will be the ones with enclosures, noise dampeners, and other materials to dampen noise. The more modern technologies like VSD, VFD, and other speed variations contribute to noise reduction with their changes in speed. Industry Air StandardsAir quality is incredibly industry dependent, this can make choosing an air compressor difficult. Someone using the compressor in their garage would not have the standards as someone who is painting cars in an auto shop. That auto shop might be held to a lower standard than someone in a dental office.If you are working in industry, your best bet is going to be an oil-injected compressor. The oil is used for lubrication, sealing, and cooling in the air compressor. This would be a great option if you have your own workshop as well. Food or medicine on the other hand, it goes without saying that you need an oil-free compressor. Your product can even harm your customers if any quantity of oil is in the air.If you are not sure where you need to be, the ISO 8573-1:2010 Standard is your best friend. It lists out the air quality classes and gives the specifications for the quantity of specific particulates, water, and oil. As long as you are meeting those standards you will be doing just fine. You will want to look into proper filtration for your compressed air system to increase the air quality. Before You BuyWell, now there is nothing left for you to learn. Take the knowledge that you have gathered to go out and buy your own compressor. Now, if it still seems intimidating, no need to fret, we have trained customer service representatives waiting by the phones to answer your questions. All it takes is a quick call.Go ahead and check out Warthog University to learn more about Compressed Air. Learn More From the Source Atlas Copco Quincy Compressors
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Common Uses of Compressed Air
Compressed Air has many uses and is vital to the success of a lot of industries, whether it be used in-house or a product earlier in the supply chain. Air is considered the 4th utility and that often gets overlooked by the general population. Something that is so prevalent is often disregarded both in usage and care of this utility. Most people don’t even know that Air is considered the 4th utility, let alone the applications where it is a necessity. Take a look around you and make note of what is sitting around you. Do you have a plastic bottle? Perhaps your medication is nearby or you took it this morning using that same water bottle. No matter your location or what you are doing the results of using compressed air can be found around you.Uses of compressed air can vary depending on the product and the industry that it is in. A paint and body shop needs air to help spray paint onto their cars, while another plant may be using compressed air to expand plastic, and a third may be using compressed air to simply move products through the facility. Air can be used for a wide array of applications and each application might use air in a different manner. How Do People Use Air? We briefly mentioned some of the versatile uses of compressed air, but the real question is how real people use it. In what ways is it benefitting these individuals? With the variety of uses available, it would take ages to talk about all of the potential uses of compressed air. Rather than that, let’s dive into some of the most common uses of compressed air. Home Uses of Compressed Air When it comes to home use of compressed air, everything from small hand-held machines to larger 60-gallon tank-mounted machines can be used. Whether it be for leisure or getting work done around the house, compressed air is used by many in their day-to-day lives. Some of these compressed air uses are: InflatingAlthough these air pumps may be simple looking and some even require manual effort to move the air, compressed air plays a large part whenever you need to inflate something. A list of common inflatables are: Bike/ Car Tires Balloons and Pool Accessories Air Mattress Sports Equipment Pressure Washing Now pressure washing may seem confusing as it sprays out pressurized water. The thing is something has to pressurize the water coming in from the hose/tank so that the water can be sprayed out and used to clean off other surfaces. Pressure washers are most often used for cleaning outdoor areas of properties. Removing dirt and chemicals from siding, bricks, and decks makes the pressure washer a valuable commodity.Woodworking and CarpentryWhen it comes to woodworking, compressed air benefits everyone from the most seasoned veterans to woodworking hobbyists. Pneumatic tools like nail guns run on compressed air and that air-powered equipment allows them to make more with less work. Air also works to help remove imperfections in the wood, help sand down the wood, and for continuous work on a median. PaintingWhen it comes to painting, compressed air is the key to efficiency. By using compressed air, the paint can be sprayed evenly over a wide area or if detail work needs to be done it can power an airbrush. Various Projects/ Yard WorkWhether it be in the garage, basement, or yard, you can benefit from using compressed air around the house. Air-blow guns can help with cleanup, or making a leaf pile for the kids to play in. It can also help you spread weed killer over large areas of your lawn without having to move. When it comes to your home there are many different applications for compressed air. Although it may not be a necessity like in industrial applications, compressed air can help make your life at home just a little bit simpler and make some menial tasks a little bit more exciting. It's extremely important to remember that compressed air needs to be used responsibly. If used incorrectly it can cause irreparable damage to you or someone around you. Small Business Uses of Compressed Air When it comes to small businesses, uses of compressed air are typically a power source for power equipment and tools used during the production process. These groups use commercial air compressors rather than consumer or industrial ones. So in short, these machines are bigger than the traditional handheld air compressors you might find at Home Depot, but not as big as the machines in an industrial air compressor room. Small businesses can be dependent on air compressors for their individual success. Most of these businesses use pneumatic tools and air compressors are needed to power those tools. Pneumatic tools provide them lighter and safer options in comparison to electric tools. These tools won’t overheat like electrical versions do after long use. This allows them to use the tools for longer without worrying about potential accidents happening with their tools. Some of the most common applications of commercial compressors include: Auto Body Shops Dentist Offices Construction Pneumatic Tools Cleaning Keep in mind that these are only some of the applications in which compressed air can be used and there are many other applications for commercial air compressors. Many individuals have even set up commercial-sized air compressors in their own homes. Industrial Uses of Compressed Air When it comes to industrial demands, some industries have no choice but to rely on compressed air. Unlike electricity, the only place of excess heat in air compression is at the site of compression. Released heat is often reintroduced at a different location to help improve energy efficiency. Removing heat makes the downstream use of air much safer. No risk of overheating and potentially causing a reaction between heat and explosive materials.The demand for compressed air has constantly been on the rise and due to this technology has followed suit and introduced different technologies like the rotary screw compressor and even more recently the variable speed drive that makes these machines, even more, energy efficient. This has allowed the uses of compressed air to expand as they were able to do more with the same machine,Industrial uses of compressed air are much larger and typically have more components in their air system than a mom-and-pop shop might have. These shops have what they need to get a small job done, but when the requirements are much steeper like an industrial application where it needs to power the whole facility and the individual components downstream. These industrial uses of compressed air can vary from agriculture and farming to pharmaceuticals. Some of these uses of compressed air include:ManufacturingCompressed air is the central power source for a lot of manufacturers, especially those working with plastics, metal, assembly, or refineries. These businesses are reliant on production and without compressed air, there is no production. Compressed air is responsible for: Operating Tools Air and Welding/Cutting Efficiently performing basic tasks Blowing plastic into a mold Monitoring Production Sandblasting and finishing meta Automated machinery AgricultureWhen it comes to farming, compressed air makes potentially difficult tasks easier. Providing long-term performance benefits alongside a low cost of ownership. Agriculture uses compressed air to move feed and grain, ventilate greenhouses, spray crops with pesticides and nutrients, and even be used as a power source for dairy machines. Farming benefits from the use of compressed air, so just remember the next time you have something with cheese, grains, or seeds that compressed air helped make that. PharmaceuticalsCleanliness is key when it comes to pharmaceuticals. We want our medicine to be what the label says it is and not have to worry about the quality of our medications. Highly regulated industries require equipment that is accurate and precise while performing at the highest level. These machines move products on the conveyor belts, spray the coating on pharmaceuticals, and bottle/package the products. Dry CleaningNow, this might be an unexpected and simultaneously obvious application of compressed air. Dry cleaning relies on a reliable supply of air to clean the items that come in and to operate machines like steamers and laundry presses. This industry is about quality and consistency and that is what compressed air grants them. Food and BeverageLast but not least, is the industry that affects us every day, the provider of sustenance that keeps us alive. They need clean, quality air to power their systems. These operations are consistently occurring to keep up with demand and with that, there can’t be any contamination. Compressed air is used to: Cool and freeze products Filling up drinks Closing and checking devices Packing and putting finished products on pallets. These industries and many more are extremely dependent on compressed air to be able to operate at maximum efficiency and maintain desired output. Compressed air is responsible for many different components of our daily lives, it also makes the production process much easier for those involved. The uses of compressed air are continuing to be expanded upon and critiques to make sure every application is getting the most out of compressed air. The only way you can reach these expectations is when you use the best products, just like the ones we carry at Warthog. Before You BuyWhether you have a current air system that needs to be updated or are looking to get your own, trust in the Atlas Copco Family of Brands. They are of the highest quality and are top-of-the-line. As they continue to push the boundaries on energy savings and technology to increase the efficiency of their machines. To get the best of the best for your personal and professional use, there is no better option than Warthog Air Compressor Store. Looking to Learn More?More From Us: Warthog UniversityMore From Atlas Copcohttps://www.youtube.com/watch?v=8XDmu7dov-Q More From Quincy
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The Basics of Compressed Air Made Easy
When we think about compressed air, it can seem like a simple concept, as it is just air that has been put under large amounts of pressure and crammed into a small space. While it may sound simple, air treatment and air systems have many complex layers to go through to completely understand how they work. We are going to be covering just some of the basics of air compression and how that is applied in industrial and individual settings.What Is Compressed Air?When it comes to compressed air, the baseline is not exactly clear on what is classified as such. Simply put, compressed air is kept under a pressure that exceeds our atmospheric pressure, and this stored pressure is used as a medium to transfer energy and power tools. The air is compressed and put under pressure by an air compressor, which can use different methods of compression with the most common being rotary screw compressors and reciprocating (piston) compressors. However, the manner of compression usually revolves around environment and application rather than the effectiveness of air output.https://youtu.be/s3DN7jbkTc0As the air is compressed and pressure is added, the space between particles is reduced and thus energy is created and held by the air under pressure. When the pressure is released, so is the energy and the air rushes out. This pressurized air is a mix of nitrogen and oxygen that help make up the ambient air around us. The energy that is created through the process of compression is directly related to the temperature of the air. The more movement of the particles the more energy that is created and the movement can be manipulated by putting the air under pressure.Some of the most common daily applications of compressed air are in balloons and sports balls. The air is blown or pumped into the container area and as that air is held in there it exists at the pressure and energy levels needed to inflate the object. When more air is added the pressure and energy increase and that is what will allow the ball to bounce higher and the balloon to expand, but if air keeps getting added the pressure will eventually exceed the vessel and it will burst or deform the container.How Does Compressed Air Work?Using the prior information to form an understanding of the nature of compressed air may lead you to wonder how compressed air has an industrial application, especially considering the most common applications you might see are used by children. The reality of compressed air is it is often unseen in its application, especially when it is used as a power source for tools and other equipment in industrial applications. The air is moved along air systems through either positive displacement or dynamic displacement.Positive Displacement: Air is forced into a confined space through the use of a mechanical device and as the machine moves the space decreases and compresses the air more.Dynamic Displacement: Rather than changing the space that the air is forced into, dynamic displacement speeds up the air itself to a high velocity to create air pressure that way.https://youtu.be/vid0ZcE5UsENot only do multiple forms exist to add pressure to the air, but the medium of compression can be different as well. Positive Displacement usually falls into two categories: rotary and reciprocating, and this explains why those two machines are the most common. These categories each have subtypes of compressors as wellRotary Compressors: Screw Two rotors are meshed together so close they almost touch, air is moved along the rotating vanes of the rotor. It's compressed down and put under pressure until it reaches the desired point of pressure as it exits the compression chamber. Scroll In a similar concept to the rotary screw, the scroll has two scrolls with one stagnant or fixed scroll and then another scroll that rotates around in a circular motion to compress the air as it moves along and the pocket of space shrinks forcing the air into a continuously smaller space until it is released at the desired pressure. Vane Rotary vane compressors use a similar idea to the scroll compressors. Rather than using two different scrolls, it uses one rotor with vane blades inserted into slots along the rotor. The rotor is placed off center so that when it rotates the vanes change the size of the space the air is trapped in and the blades slowly slide back in the vane as the space is reduced to add pressure. https://youtu.be/b93GSe-xgqIReciprocating Compressors: Piston Piston Compressors are the main type of reciprocating compressor to the point where piston and reciprocating can be used interchangeably. They operate in a manner identical to internal combustion engines. You know the ones that power most of our cars. Except instead of the energy from combustion being pushed through, compressed air is the byproduct. The crankshafts control the rods and pistons that are responsible for compression, and as it rotates the piston moves through the cylinder to compress the air, and then when it pulls back to go again the first pocket of compressed air is moving towards the next step. The output or pressure can be varied by the number and size of pistons on the crankshaft. Air quality is another factor that is extremely important when it comes to air compressors and the air byproduct. Many instances where compressed air is used as a source of energy are riddled with safety standards and specific quality standards that need to be reached. In instances like that are perfect for an oil-less air compressor. Compressors of this nature use a different material forStandard Applications of Compressed AirNow you might be wondering where compressors are used or what a good application for compressed air would be. Compressed air is a medium for transporting energy to power equipment like drills, hammers, wrenches, and more. They are used during construction as the air does not increase the likelihood of a fire occurring like electric or gasoline-powered equipment. This also allows for the use of equipment in less than ideal places or in places where electricity might not be available thanks to tow-behind compressors that can be moved around to where it is needed.The application of compressed air is extremely versatile but it typically is used in specific industries due to its effectiveness. The most common applications are instances where cleanliness and precision are high priorities. These industries include but are not limited to:Food & Beverages The use of compressed air in food and beverage is simple yet necessary. They remove particulates and ensure the cleanliness of the product. Compressed air is used for a variety of reasons from capping bottles to the fermentation of food and liquids. This process is used in brewing beer and by major beverage consumers as well. Air can be used to move products along the production line, the final packaging, and movement of product components. Pharmaceuticals Compressed air plays a major role in pharmaceutical production from cleaning and aeration to product movement. The air is monitored very strictly in this application due to the products needing to be safe, clean, and consistent. Compressors are often oil-free with an emphasis on filtration to reach the sterile environment expectations. It is due to compressed air that products like lactose enzymes are able to be reliably isolated and produced for those who are lactose-intolerant as well as the coating on tablets to prevent the bitter medicinal taste from coating your mouth. Chemicals When manufacturers are producing chemicals they want to rest assured of the quality of their products. Clean compressed air can assist in the handling of materials, creating air curtains for isolation purposes, and drying products. Oil-free air is a necessity due to strict safety standards and the potentially negative downsides. The potential mixing of chemicals with oil is something we want to avoid. Automotive The automotive industry is one of the major users of compressed air due to the precision required for success. Whether an outer coat of paint or the fastening of internal components, precision and accuracy are of high importance. Air tools are prominent in maintenance and routine tasks like putting air in the tire. The quality of the products is dependent upon the quality of the air. Industrial The use of compressed air is quite prominent in industrial applications. Compressed air is used in places like construction sites, mechanic shops, road maintenance, factories, and other similar places. Compressed air can power tools needed for many different industrial processes. Electronics Electronics is another industry where it might not be obvious why compressed air is used. It is used for the production and assembly of intricate pieces to help ensure quality. Equipment like circuit boards, wafers, memory chips, and other internal computer components use compressed air. The air does not stop there, it also polishes and cleans the finished products to ensure the removal of chemicals. Compressed air may not seem prominent, but it is indeed a heavily relied upon utility. It is so common to the point it is often referred to as the fourth utility. Compressed air is crucial when it comes to productivity and is one of the most environmentally sound options. The industries that were previously mentioned are only some of the industries and environments in which this energy source can be used. The widespread quantity of air makes it an extremely valuable source of energy as it can be used in so many different applications.Looking For Your Own?If you want to look at our compressors, click hereIf you would like to learn more, click hereFrom the ManufacturersFrom Atlas Copco Compressor Basics Compressor Applications
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What is a Variable Speed Drive Air Compressor?
The Basics of a Variable Speed Drive Air CompressorVariable Speed Drive air compressors, also known as VSDs, are rotary screw compressors where the motor operates at different frequencies depending on the demand that is being placed on the compressor. These compressors alter the RPM of the motor to match the CFM that is required at the moment. When demand is low, the compressor will work at a lower RPM, reduce the amount of energy being used, and use the full amount of energy and output when necessary. The reduction in RPM to match demand makes the variable-speed drive air compressor a much more cost-effective option when it comes to total power use than the traditional fixed-speed compressor.A fixed-speed compressor would use much more energy over an extended period of time compared to a VSD. These may use less energy when it is not under load, but that can still be up to 70% of the power the compressor uses to keep the motor idle until it is used again. For example, if there are two 150HP compressors, one is a traditional fixed speed compressor and the other is a variable speed drive air compressor, while at full load, they will both use the same amount of power needed in order to meet the demand.Dictated By DemandIf the demand is lowered, the fixed speed will continue operating at the same level of energy consumption. However, VSD will lower its RPM to meet the demand of the air compressor. Meanwhile, even though the demand is lower, the fixed speed will still be running at the same energy level as at full output. Even when demand is almost completely reduced the fixed-speed compressor will still operate at about 70% power while the variable-speed drive air compressor can even shut off completely and start back up when there is a demand.https://www.youtube.com/watch?v=F_YQmjW2TVYThe Advantages of a Variable Speed DriveEnergy EfficiencyA simple rule of thumb can be used to determine its energy efficiency: Energy consumption is a reflection of demand. The higher the demand on the compressor, the higher the energy used, and the lower the demand, the less energy is being used as the motor's RPM is ramped up or down to match.This can reduce energy costs to over 50% due to the efficacy of the motors. This change is a worthy investment in the long run as the energy savings almost erase those initial costs. When it comes to the drivetrain of the motor on the VSD, it is directly connected to the screw elements which allows for the motor to be completely shut off when it is not used rather than having to sit in idling and draining power.When it is nearly completely shut off it vastly reduces the energy consumed by the compressor. This ability to partially shutdown and restart on demand is due in part to the "soft start" of these motors as the RPM increases to the point that is needed, so as the motors ramp up, the energy level does as well, which reduces the energy spikes, unlike fixed speed which need large amounts of energy to start.Increased System LifeThe variable speed drive air compressor systems only operate at the required level at the time. Therefore, they are not always running at full power and output. This is easier on the machinery in the long run; it works half as much as a fixed speed would in a similar amount of time.The efficacy of the starting and stopping processes also reduces the wear and tear on the machinery. The machine slows down rather than coming to a hard stop when it is no longer under load. The characteristics of variable speed drive air compressors also benefit the motor and overall performance.Potential Energy IncentivesThe variable speed drive air compressor is more energy efficient because it matches demand. Power companies may also incentivize people to switch to a more energy-efficient compressor, like the VSD. These compressors benefit both parties as the energy consumption is reduced for the individual using the variable speed drive air compressor, and the power companies benefit from the reduced grid strain and decrease in energy spikes that can potentially cause power outages.Additional Benefits of the Variable Speed DriveThe energy reduction is one of the big reasons for individuals to switch to the VSD, but that is not the only reason that the switch is beneficial for consumers. One of the factors that really separates the variable speed drive air compressor from fixed speed compressors is its pressure control capabilities. Most fixed speed compressors can have a standard deviation of +/- 10-30 PSIG and such high variability can cause inconsistencies across the plant, where if a Variable Speed was in place, they have a standard deviation of +/- 1.5 PSIG which allows for a much tighter pressure band and creates more consistent air pressure throughout the facility.Working within such a tight pressure window allows for a lower delivery pressure for consistent pressure. An overall increase in production due to being able to reach higher production levels, reducing mistakes due to inconsistent air pressure, and smoother overall operations. Production is smoother, and the VSD compressor requires less frequent maintenance. Not operating at full capacity all the time means less overall usage. The system undergoes a lot less “instant shock” and reduces and potentially eliminates water hammer due to the smooth acceleration and deceleration.The Short of the Benefits The VSD compressor only runs when needed, reducing energy costs. Typically, it is enough to pay for the additional investment in VSD technology. A variable-speed drive air compressor can start/stop under full system pressure. There is no need to unload, which saves both time and energy. No time is lost to idling. No blow-off losses occur in normal operations. Power company penalties for peak current at startup are avoided. Air system pressure is more consistent and also lower, minimizing leakag. Looking for More?If you are looking for more information consider going to Warthog UniversityInterested in getting your own VSD?More From Atlas Copco
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