What is Compressed Air?

Many industries use compressed air, so much so that it is often referred to as the fourth utility.

Air-powered systems utilise compressed air, such as factory conveyor belts and pneumatic tools. They depend on compressed air for operation and are ineffective without it. Compressed air acts as stored energy in a different form.

Once air is compressed using local ambient air sources, it is immediately usable and can be stored or transported. Air tanks can store compressed air on site for later use. Compressed air is transportable in pressurised canisters and distributable between work sites.

Compressed air can be produced on site or by a third-party supplier. Producing on site offers considerable long-term cost savings, plus pressure levels and other factors are more configurable.

Definition of Compressed Air

Air compressors work through the intake of atmospheric air. Different forms of mechanical compression are applied to compress the air into a smaller volume. When air is forced to occupy a smaller space, this creates air compression above normal atmospheric pressure levels.

Typically, atmospheric air comprises 21% oxygen, 78% nitrogen, and 1% from other gases. Therefore, while we refer to ‘breathing oxygen’, ambient air only partly consists of oxygen.

As stored potential energy, pressurised air can be fed through a network of air ducts or directly into air-fed machinery.

How is Compressed Air Generated?

Compressors generate compressed air by applying pressure to it. This process involves taking in non-pressurised air, filtering it, and then channelling it into an internal pressurisation chamber. The air is then mechanically reduced in volume.

When forcing air to occupy a smaller area, it becomes pressurised. All compressors achieve this objective in different ways. Below, we run through some of the different types of air compressors available.

Reciprocating Compressors – these compressors use pistons, moved by a rotating crankshaft, to create a reciprocating system to compress air. They work well but often create more wear and tear.

Rotary Screw Compressors – these compress air by rotating two large screw-shaped parts inside the compression chamber. These create less wear and tear compared to reciprocating compressors. Industrial operators often use rotary screw compressors.

Centrifugal Compressors – to generate pressurised air, a spinning impeller moves rapidly and continues accelerating. These are most often found in huge industrial operations rather than smaller ones.

To learn more about the types of compressors available, please get in touch with Anglian Compressors.

Applications of Compressed Air

There are numerous applications for compressed air.

Some are utilised in industrial settings, while others are used commercially. Some have more specific applications for small businesses or personal projects.

Industrial Uses

Compressors used in an industrial setting have a wide range of applications.

Large pneumatic air tools require substantial volumes of highly compressed air. Grinders, sanders, drills, and other workhorse tools are good examples.

Automation is a growing segment within the manufacturing sector. Automated valves are activated using pressurised air instead of relying on human activation. Pneumatic cylinders are also actuated similarly.

Factories make use of industrial-strength air blowers. These provide essential cleaning operations to clean pipes safely and other difficult-to-access areas.

Commercial Uses

Compressed air is part of HVAC control systems in commercial buildings, office parks, and elsewhere. The compressed air plays an important role in controlling valve settings, reducing the human oversight required for the typical HVAC system.

The healthcare field and dental clinics depend on pressurised air, too. Air-powered drills are used during dental operations, and sterilisation tools are essential in the medical field.

Pressurised air helps inflate low-pressure tyres at the petrol station and powers pneumatic air tools in the vehicle workshop. These tasks require access to large volumes of compressed air; otherwise, their customers get impatient and take their business elsewhere.

Everyday Applications

At home, small air pumps are used to inflate sports equipment, increase bike tyre pressure, add extra air to motorcycle/van/car tyres, and more.

Airbrush paint jobs and spray painting are completed using specialised spray equipment. This is connected to a steady supply of pressurised air.

Compressed air is also used for general cleaning tasks. During IT repair, canisters of sanitised pressurised air are used to clear away dust from inside PCs, laptops, servers, and other sensitive equipment. Also, dust is quickly removed using portable duct vacuums.

Benefits of Using Compressed Air

There are various benefits of using compressed air. Below are a few of them.

Compressed air is a fantastic medium, an efficient energy source, and has minimal environmental effects.

While air systems consume a good amount of electricity, the heat produced through the compression process can be harnessed to provide building heating and hot water to bathrooms. This reduces electrical bills for these related expenditures.

The electrical power is safely used. Even in explosive or hazardous environments, running air compressors is safer because there is minimal risk of producing electrical sparks.

Generated compressed air is not lost. Even when downstream equipment does not require all the air generated, it is easily stored on site inside air tanks without significant loss of energy or air quality. Alternatively, safely transporting it off site is possible, too.

Compared to other mechanical energy transmission forms, compressed air does not weigh you down with maintenance requirements.

Safety Considerations

Like all industrial or commercial equipment, air systems have safety considerations. While these should not deter you from using them, prioritising safety is essential.

Understand the Risks

Operating loud, sizable equipment, including those with moving parts or air pressurisation systems, introduces the potential for injury or worse.

During operations, some possible risks include ruptured hoses flailing around and impacting someone, an air injection injury, or potential flying debris from a part coming loose.

Also, compressors are louder than some other machinery. Long-term exposure without ear-worn protection can cause hearing damage at higher decibel levels.

Rarely, there are situations where compressed air enters the human body. This can cause air embolisms in the stomach or lung areas. Such injuries are often severe and can be fatal.

An abundance of caution is necessary around air systems to ensure everyone’s safety.

Best Practices for Safe Operation

Following air system best practices is necessary to operate safely.

Regularly inspect air compressors, air dryers, connected hoses, ducting, and other aspects of the whole air system. Complete preventative maintenance of air compressors and hoses to avoid a part failure or a fitting/hose working loose.

All operators must receive proper training. Focus training on operating the system, proper handling, known hazards and risk factors, and what to do in an emergency. Run safety drills to avoid the training getting stale or forgotten.

Do not allow any unnecessary access to the compressor area or compressor room. All staff accessing these areas must wear protective equipment, including ear defenders and eye protection.

Need tips on how to make your compressor room safer? Ask our qualified personnel at Anglian Compressors for professional advice.

Environmental and Economic Impact

Compressed air generation is heavily energy-intensive. Depending on the industry, approximately 10 per cent of all industrial-based electricity is consumed in compressed air production.

Improving Energy Efficiency

Air compressors are becoming more energy efficient. Atlas Copco now produces variable speed drive compressors. These produce compressed air at the precise flow rate and compression level required.

Heat recovery systems harness waste heat to produce hot water year round and heating during the colder months. This reduces related energy expenditures in these areas.

Leaking air systems throw money out the window. Compressors must produce extra compressed air to compensate, increasing operating expenses. Air leak audits are worth considering because they can find and highlight current air leaks requiring fixes.

Another area is air quality management. It is often overlooked but can be beneficial. Drying air saves downstream air tools from subsequent damage. Air filtering protects your air system investment in the long term, and filters should be changed regularly.

Economic Considerations

Choosing an air compressor with lower operating costs and better environmental ratings is a win-win. Admittedly, it comes with the initial investment cost, but money is saved by operating it more efficiently over its lifespan.

When replacing an older compressor, the savings become readily apparent once the replacement compressor has been operating for a few weeks.

Regular maintenance provides significant cost savings. It helps operations run more efficiently and prevents wear caused by inadequate maintenance schedules. New compressor owners experience fewer unexpected breakdowns.

Conclusion

Compressed air is essential in today’s world. Numerous industries rely on compressed air to operate safely, efficiently, and at a lower cost.

Producing compressed air on site is less expensive than purchasing air supplies and waiting for deliveries. When deciding to generate compressed air, be sure to understand the benefits and the safety considerations, too. Adopting best practices saves a lot of headaches later.

Please get in touch with our team at Anglian Compressors for a free compressed air consultation today.