Oil-containing and contaminated compressed air can deteriorate compressor components as well as integrated systems. The air compressor oil separator is a separator tool that is used to separate the oil from compressed air almost completely.
In this comprehensive blog post, we will unravel every detail of the air compressor oil separator. Stay tuned!
A] What is an Air Compressor Oil Separator?
The compressed air oil separator is a filter that is used to separate oil from compressed air. It is strategically placed at the point where compressed air exists. The strategic location allows the oil separator to filter out every oil-containing microdroplet from compressed air and deliver oil-free air to associated systems. After separation, compressed air only contains less than 1 ppm (parts per million) of oil content in the compressed air. Also, using a compressor oil separator offers an array of benefits, including protecting systems components, preventing contamination, and maintaining product safety and efficacy.
B] How does the Oil Separator Work?
When high-speed oil-infused compressed air enters into a cylindrical oil separator chamber tangentially, the tangential entry of high-speed air causes the air to spin rapidly. The rapid air spin generates centrifugal force and eventually separates the oil and air. Now, the coalescence effect merges separated microdroplets into a single drop. Further, these oil drops are collected at the separator’s bottom. These collected oil drops are stored in the catch can and returned to the compressor’s oil sump. Consequently, clean and oil-free compressed air is delivered to the pneumatic systems.
C] Benefits of Air Oil Separator
1. Maximum Oil Removal
Oil separator for air compressors utilises highly efficient coalescing filters to remove oil from the air as low as 1 ppm. The combination of centrifugal force and filter promotes maximum oil removal from compressed air without affecting the airflow output. Clean and oil-free air ultimately enhances the associated system’s efficiency and decreases the cycle of maintenance work.
2. Enhanced Air Quality And System Efficiency
The air compressor air oil separator removes most of the oil and contamination from compressed air, providing clean and optimal-quality air to the system. The oil-free and contamination-free air allows the associated system to work without friction. It allows systems to perform at their optimal level, boosting system and process efficiency.
3. Reduced Wear And Tear On Equipment
Contaminated air can cause rust, erosion, and sludge formation within the system, which further leads to wear and tear on equipment. Oil separators eliminate the formation of these contaminated air-borne causes and safeguard systems from being contaminated. The friction-free system operations mitigate the possibility of wear and tear and further enhance the process efficiency.
4. Cost Savings On Maintenance And Repairs
Oil-containing compressed air collects dust and debris from surroundings. These contaminations further influence the system’s performance and cause rusting to internal parts. It leads to frequent maintenance and repair. Oil separators provide clean air to the system, eliminating the likelihood of system rusting. A rust-free system operation allows industries to save costs on frequent maintenance and repair.
D] How To Spot Signs Of Oil Separator Failure
1. Visible Oil Leakage
If you see oil drops leaking from the oil separator, it is a sign of a compromised separator. A compromised separator decreases its oil removal capability, creates pressure on the compressor, and further hinders process efficiency. Therefore, it is essential to repair or replace the separator if any visible oil leakage is observed.
2. Significant Pressure Drop
A visible air pressure drop is also a sign of a malfunctioning oil separator. In addition, a clogged filter also prevents complete air passage and reduces the air pressure. Therefore, it is essential to perform a thorough inspection and replace the faulty component, if any.
3. Air With Excessive Oil Content
Air with excessive oil content is also a notable sign of a compromised oil separator. In this case, the separator fails to reduce the oil content from compressed air, which further deteriorates the associated systems. Perform a thorough inspection to repair or replace faulty components of the oil separator.
4. Unusual Noise & Vibration
Unusual vibrations or strange mechanical noises are other signs of a faulty oil separator. It affects lifespan and reduces the overall performance of the oil separators. So, it is important to thoroughly assess and repair if strange noise or vibration is observed.
E] Tips for Maintaining Air Oil Separator
1. Periodic Inspection
Periodic inspection and proactive maintenance enhance the oil separator’s lifespan and maintain its optimal efficiency. The periodic inspection should involve an oil leakage check, air pressure assessment, observation of unusual noise and vibration, and evaluation of oil content presence in compressed air.
2. Regular Oil Change
Changing the oil at regular intervals is essential to keep the efficiency and quality of the oil separator intact. It enhances the performance and keeps the contamination and other wear and tear issues at bay.
3. Replacement with Genuine Parts
Whether it is an oil separator or air compressor parts, replacing faulty components with genuine ones is highly essential. Genuine parts are calibrated as per the equipment’s design and they integrate seamlessly without any fitting issues. In addition, they also help maintain efficiency and prolong the system’s life.
F] Choosing the Right Oil Separator for Your Air Compressor
1. Efficiency Rating
Efficient rating indicates its ability to remove oil from compressed air. A high-efficiency rating oil separator reduces maximum oil carryover without straining on compressor. One should always choose those separators that have the highest efficiency ratings. However, one can opt for oil-free reciprocating compressors, which are designed to provide oil-free compressed air. It eliminates the maintenance intricacies of oil separators and offers clean and contamination-free air throughout the integrated systems.
2. Compatibility with Compressor Types
Before choosing the right oil separator, one should always assess compatibility with the compressor. The airflow rate and operating pressure should also be assessed to eliminate the compatibility and functioning issues later.
3. Operating Conditions
A harsh and dusty environment can clog the separator’s filter more often. It may lead to maintenance costs and a reduction in process efficiency. Choose those air oil separator filters that can withstand harsh operating conditions. However, one can easily eliminate these intricacies of finding the right oil separates by opting for an oil-free scroll compressor. It provides oil-free compressed air and can withstand any harsh conditions without dropping its optimal performance.
Conclusion
The air compressor oil separator works wonders in providing oil-free and contamination-free compressed air throughout the pneumatic or other associated system. However, there are more options available, such as oil-free scroll compressors or oil-free reciprocating compressors to eliminate the separate attention to be paid to maintaining the oil separator. Opting for these options will be a wise choice as it will save time and let you focus on your core competencies.
Bimpex India is a leading and renowned manufacturer and supplier of industrial air compressors. We offer heavy-duty and high-performance oil-free scroll compressors and oil-free reciprocating compressors at affordable prices. Thousands of our customers are using our oil-free compressors happily and hassle-freely. Contact us today to get our oil-free compressor solutions for your business.