NEC Air filters mostly called as air line filters it was used in condensed air lines as a way to stop liquids and solid contaminants from entering air compressors. They stop these contaminants from entering the equipment and causing damage. A cubic foot of compressed air may harbor millions of dust particles. Significant amounts of oil and water. Depending on the application, the compressed air might even contain lead, mercury or other heavy metals.
And Most Importantly Air compressors without installing filters , not removing such contaminants of critical system , it shows as cylinders and valves will be damaged . Air filtration is one of the essential element of proper compressed air. This Preparation can prevent seals from premature wear . In conculsion to reducing downtime, clean compressed air results in lower energy costs.
Air Filters working Priniciple
Air Filters work by straining air to trap solid particles and separate liquids from compressed air. To Identify the above processing , it help us to find out the main components parts found in Air filters
- Inlet: The air compressor intake or inlet is where air enters the filter. There is an internal cap that forces air downward into a spiral.
- Filter cap: This component directs airflow through the filter.
- Air path: This is the actual path the air follows as it spins like a cyclone and passes through the air filter itself.
- Filter discharge: This orifice allows air to leave the filter, and it should match the inlet size. If the filter discharge is too small, it will restrict the flow of air.
- Element: Filter itself is what takes contaminants out of the air, catching particulates over time.
- Filter bowl : Bowl is the biggest part and connected at the top portion.
- Filter quiet zone: Contaminants, water and oil collected by the filters all end up in the quiet zone at the bottom of the filter.
- Drain : The Water Collected contaminants debris have to be remove.
In the first stage of filtration, compressed air passes through a mesh filter.
Quality Air Required for the Pneumatic Application
Quality Air Required defined by the international standard ISO 8573-1 : 2010. The standard uses class ratings for solid particles, oil and water condensate content, with scores in these classes ranging from one to nine.
Your applications and processes determine how clean your air needs to be. Many pneumatic applications of compressed air need a standard dry particulate filter. Other processes may require OSHA-approved elimination of vapours and aerosols. Refer to factory recommendations and specifications to determine the air quality you need.
Principle of Air Water Separators
Water condensed from the ambient air will accumulate without a water separator, and will cause damage to the compressor and connected components if not removed by a water separator.
Water separators use one of two methods to remove condensate:
- Centrifugal separators create a rotary motion that causes particles to radiate outward as they accelerate. As the particles reach the outside of the separator, they drain into the filter bowl. The great advantage of centrifugal separators is that this process does not require maintenance.
- Coalescing separators cause air to flow from the inside of the filter element to the outside. This type of water separator for air compressors, have to replace the filter cartridges frequently.
Effects of Water in Compressed Air
Water in your compressed air system can cause costly damage very quickly, creating the need for compressed air dryers and filters that remove all moisture.
- Eroded lubrication, leading to wear and tear or rust on the moving parts of the compressor.
- Lack of consistency in spray paint applications, leading to non-uniform tone, adherence and texture on painted products.
- Formation of ice in control lines, leading to malfunctions in essential controls.
- Corrosion of connected tools, leading to everything from incorrect readings to failures in factory operations.
The presence of moisture in compressed air creates a domino effect for every connected component that requires pneumatic controls.
Water Damage and Pneumatic Equipment
If Air carries moisture and oil contaminants it will damage the pneumatic parts. The cylinders will worn down more quickly. This creates a more frequent need for repairs on bearings and seals. As water is a universal solvent, moisture degrades essential lubrication that keeps all the moving parts in air cylinders functioning smoothly, resulting in a heightened risk of malfunctions.
In this the vaporized air passes through the spools, pistons and valve diaphragms in pneumatic tools . It happen hardening that will prevent causes these components to damages. No matter the application of the air, moisture in it will wear down cylinders and decrease efficiency at the very least. The above Instrument of air lines , it will corrode and moisture produces.
Types of Inline Air Compressor Filters
Compressor systems may use a variety of inline filter types to ensure high-quality air. These types of filters will have special unique benefits for compressed air treatment systems :
1. Particulate Filters
The dry particulate filters are help to remove particles from the adsorption dryer. It used to remove corrosion particles from the air. A particulate filter captures particles and traps them within the material of the filter.
2. Activated Carbon Filters
These filters use surface-active adsorption to bond odorants, and oil vapors. Carbon filters are essential to ensure compressed air oil removal.
3. Coalescing Filters
A coalescing filter is help to remove water and aerosols from air.
This type of filter removes dirt, dust, water aerosols and oil down to 0.01 microns, making it an effective choice for air dryer pre-filters.
4. Cold Coalescing Filters
The variation of coalescing filters tested at 35 degrees . Operating them at low temperatures increases efficiency in moisture removal.
5. Compressed Intake Filters
The air compressor intake filter is essential as the first defense against contaminants. An intake filter can block particulates as small as 0.3 microns and helps remove chemical contaminants from the air.
6. High-Efficiency Filters
The High Efficiency filters are the better filters compare with other filters . Working to removing particulates and reducing air pressure drop. It will take less energy comparing with other regular filters . It will help to remove the small particles as small as 0.01 microns.
How to Choose the Best Filter for Your Air Compressor
Selecting the best air compressor filter for your system is one of the best things you can do to preserve efficiency and prevent unnecessary wear on your equipment. Choosing one or more air compressor filters can be a challenging task.
Every type of air compressor has its own set of fittings, filtration and other requirements you must take into account. The only way to narrow down your options for air filters is to refer to the manual and instructions for your system. If you no longer have the manual, it’s a good idea to consult a reputable company that can help you track down the specifications for your particular type and model of compressor.
Quality and Efficiency
Filters use a certain amount of energy based on how much they restrict flow. The Filters are made with special attention of high efficiency to remove the water and particles . It minimizing the pressure level drop. Like any product, there is considerable variation in production quality, and choosing a unit from high-quality compressed air filter manufacturers will improve your end result.
The lower the filter quality, the higher the pressure drop and rate of clogging. To Save a money on a filter upfront . Only it ends up costing you more in the long build run. And more advanced ability to trap contaminants with less of a pressure drop results in better efficiency and longer intervals between replacement . If you are concerned with achieving optimal quality, it may be a good idea to purchase and test multiple filters side by side to more directly compare their performance.