An air compressor is an essential tool in almost every industrial sector. It plays a significant role in operational activities such as manufacturing, packaging, and other tasks. The device has endless industrial applications, such as powering up pneumatic tools, inflating objects, applying coating, and cleaning surfaces. Any industrial process that needs construction, metal fabrication, woodworking, and painting coating needs an air compressor.
Do you know which air compressor type is in higher demand? It is an oil-free air compressor. In some of the hazardous industrial processes, oil-free air compressors will reduce the risk of explosions. Moreover, it will provide an oil-free clean air supply to industries that depend on it. These industries include food & beverage, pharmaceuticals, hospitals, and chemicals and glass Industries which require oil free clean air. The device will increase product purity and produce less waste. This is why oil-free compressors are in higher demand in the food and beverage industry, the pharmaceutical industry, the petroleum industry, and others.
This blog will give you a brief understanding of oil-free air compressors, their working mechanism, and other details.
A] What Are Oil-Free Air Compressors?
Oil-free compressors are a type of air compressor that uses specific technologies that eliminate the need for oil. It does not use any oil or lubricant for lubricating action.
The difference between oil-lubricated and oil-free compressors is vast. But in general, oil-free air compressors use specific types of pre-lubricated materials such as Teflon. This will coat the compression elements instead of the use of oil. But, oil-lubricated compressors need oil to run the industrial process. Being one of the prominent air compressor supplier in Mumbai, we have different types of oil-free air compressors to meet your industrial needs.
Oil-free compressors are considered safer with the purest air supply in the production process. Moreover, it produces less waste and reduces the chance of explosion and hazardous disruption in the production process. This is why they are important in food processing, pharmaceuticals, electronics, and medical industries.
B] How Do Oil-Free Air Compressors Work?
Wondering How Do Oil-Free Air Compressors Work? Its working mechanism is explained in the below stepwise process.
Step 1: Take In Air
Oil-free compressors will start working by letting in the outer air with the help of an unloader valve. It will pass the air through inlet air filters to make sure the air produced is clean.
The unloader valve will let the compressor pump air to get to the chamber. After the valve is closed, the compressor will enter into the “unloaded” position and start running. While the compressor is running actively to deliver compressed air, it will not draw in more air into it. Once you turn the compressor, it will start to draw air in through the open unloader valve.
Step 2: First Compressor Element
After you have noticed that the air compressor is generating heat, this is due to the low-pressure compressor element as it is working without any lubricant or oil. An average compressor element operates at 2.5 bar pressure. The compressing air has the ability to let the unit operate at a temperature of a maximum of 180 degrees.
It can be double the temperature of an oil-lubricated compressor’s reach. This is due to the absence of a flowing medium like oil that can reduce heat. Oil-free elements can compress the air and move through the compressor to cool down the air in order to use it for various applications.
Step 3: Intercooler Access
After the air is compressed, the pistons in the compressor will push the air with the help of an intercooler in order to cool down the air, which has to be compressed further. Based on the specific compressor, this intercooler step may shift to the second compression phase or directly to the final one. The cooling air will get condensed.
Therefore, the intercoolers are incorporated with standard filters, which are engineered to remove water and moisture from the air. This filter is also known as a moisture trap. Once the air is cooled, it will return to the compressor for extra compressing. You can check out the difference between an air compressor aftercooler vs an intercooler to make the right choice.
Step 4: Higher-Pressure Compression
Next, the air will get back into the key chamber of the oil-free air compressor in this step. Or, it will get back to the second chamber based on the compressor’s design. Later, it will be compressed with a high-pressure element.
The maximum pressure amount ranges between 116 to 145 psi. Again, the air will become too hot because of the lack of oil in the surrounding elements. Therefore, it has to be cooled again.
Step 5: Air Prep and Aftercooler Access
After the second phase of compression, the air reaches temperatures of 150 degrees and needs additional cooling before it is used in industrial applications. So, the air will pass on to the aftercooler for the final compression. In this cooling process, the air will be securely stored.
After the air passes through the aftercooler, it will move to the check valve, which prevents backflow. Moreover, it will make sure that the air compresses continuously and fills in the tank. The air will be finally stored and used for further application.
Step 6: Pressure Switches
The oil-free compressor has detection equipment that monitors the air level inside the compressor. After it falls below a specific level, the air compressor will work again to rebuild the compressed air.
The pressure switch is used to monitor which turns on and off the air compressor. These switches are usually attached to the unloader valve, even if the valve is located internally. The switches will be set by the factory.
C] The Oil in Oil-Free Air Compressors
Do you want to know how are oil less compressors on recovery units lubricated? Basically, oil-free air compressors do not use any oil in the compression chamber. Instead of oil, other alternative materials are used, for example, Teflon or water, in order to protect the components from wearing out.
It will allow the compressor to work smoothly without the necessity of oil-based or any other synthetic lubricants. However, in oil-free compressors, the gears and bearings still need lubrication as they are located external to the compression chamber; with the help of secured sealing of the gearbox, it will ensure that oil is not contaminated by any means.
D] How Long Can You Use Oil-Less Air Compressors?
In general, the oil-free air compressor has a shorter lifespan compared to oil-lubricated compressors. This is because the pre-lubrication gets worn out and degrades with time. Also, oil-free air compressors use a universal motor, which may not have a longer lifespan than an induction motor.
Also, in oil-free air compressors, seals have to be replaced in between 2,000 to 8,000 hours of operation. It is also based on how hard the compressor is used and also on factors such as design and sealing material type. Overall, oil-free air compressors last around 200 hours, and higher-end ones will last up to 2,000 hours.
E] Types Of Oil-Free Air Compressor
- Oil-Free Reciprocating Compressor
The Oil-free reciprocating compressor uses positive displacement that releases air pressure through two sides, either through suction or by the discharging process. These reciprocating compressors consist of permanently lubricated bearings.
- Oil-Free Scroll Air Compressor
The oil-free scroll air compressor is incorporated with advanced scroll technology that includes mobile and stationary spiral systems. These systems work together to bring air into the compression chamber.
- Oil-Free Screw Air Compressor
The Oil-Free Screw Air Compressor also generates air compression using displacement and by running interlocking screws that operate to draw in air. Later, it will pressurise them in a smaller area.
F] Benefits of Oil-Free Air Compressors
The oil-free Air Compressor has a lot of benefits that will make your industrial process more productive.
Reduces Overall Ownership Costs
The tool will cut down costs in various ways. It will reduce your energy charge. There will be no cost of oil-laden condensate disposal, and it also eliminates the oil replacement.
Lower Contamination Rate
Oil-free compressors lower contamination risks with a pure air supply. It will keep up your brand reputation by raising your standards with a safe product supply.
Multiple Applications
These air compressors come with a wide range of applications due to their lightweight, small size, and efficiency. Moreover, you do not have to worry about oil leakage.
Eco-Friendliness
Oil-free air compressors lower environmental impact. As it produces less waste, it is not harmful to the environment or your employees.
Operates Faster
Oil-free air compressors usually work more rapidly, which results in great efficiency in your industrial process.
Clean Air
Clean, oil-free air is an essential requirement for several industries, including food and beverage, medical, pharma, hospitals, glass, and chemicals.
Conclusion
This is your comprehensive guide to how do oil-free compressors work and other necessary details related to their working mechanism. Oil-free compressors will be a valuable addition in industrial sectors such as medical, pharmaceutical, and food and beverages as the tool has a low risk of contamination.
However, the benefits discussed show that it will be the best air compressor type for all industries as it reduces overall costs and has multiple applications. If you want to invest in high-quality and certified oil-free compressors, Contact Us now!