Friday, August 30

Air Compressor Cooling Systems 101

Air compressor cooling systems are important for many compressed air systems, whether they are in warm climates or not. Air compressors themselves generate a lot of heat, so it is important to cool the air down to prevent damage to equipment, products, or personnel. Let’s dive into cooling systems in more detail:

What Is an Air Compressor Cooling System

Air compressor cooling systems safely remove excess heat that is created during the compression process and discharges it to an appropriate area where it will not pose any risks to surrounding people or equipment. This leaves the compressed air in a cooler state appropriate for use in whatever application it is being applied to.

Types of Cooling Systems

Intercoolers

Intercoolers removes excess heat before the air enters the engine intake. Intercoolers allow for greater ai flow into the compressor by raising the air’s density which also boosts the compressor’s efficiency.

Aftercoolers

Aftercoolers cool the discharged air while also removing moisture that could cause damage to the piping.

Air-Cooled
- Air cooled aftercoolers utilize the air around the machine, also known as ambient air, to bring the temperature of the compressed air down and transfer the excess heat elsewhere.
Water-Cooled
- Water-cooled aftercoolers utilize circulating water to lower the compressed air temperatures. Water cooled compressors may use just water or they may use other coolant liquids to achieve this result.
  - Closed-loop water cooling: this type of water-cooled aftercooler recirculates the same water throughout the system and utilizes a heat exchanger to cool the water down before beginning the cooling process again
  - Evaporative water cooling: this type of water-cooled aftercooler utilizes a continuous supply of fresh water to cool the coils containing compressed air.

Cooling System Comparison

Why You Need a Cooling System

As mentioned earlier, air compressors generate a lot of heat. The more air that is compressed the more heat that is generated. The standard industrial air compressor can reach temperatures of 300 degrees Fahrenheit and above! These high air temperatures are not suitable or safe to come into contact with humans, other equipment, or the point-of-use application. This is where cooling systems come into play, they cool the air before it travels downstream to where it could pose a very severe risk of damage if it stayed at that high temperature.

Excessively high air flow temperatures can result in the following issues:

Compressor overheating
Excessive wear-and-tear on internal components leading to early failures of various system pieces
Increased environmental heat that can put strain on other HVAC systems
Damaged end products
Injured employees

So, by removing this excess heat, you will deliver a higher quality of compressed air, ensure safer operating conditions, and increase the longevity of your system.

Selecting & Sizing the Right System

Choosing the proper cooling system for your air compressor is crucial to extending your systems lifespan, ensuring optimal functionality, preventing overheating, and maintaining workplace safety. Factors including the size of compressor, type of compressor, and environment the compressor is in play a large role in deciding what kind of cooling system to install. Variables in your compressed air system like CFM, PSI, discharge temperature, and ambient temperatures will dictate sizing needs. You should always consult a professional when deciding on a new system component and for proper sizing recommendations. Reach out to Zorn Compressor for help when choosing the right cooling system for your air compressor.

ZORN'S PROMISE

Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction.

Our comprehensive product and service solutions keep you running 24/7.

Reliable equipment
Trusted brands
Seamless, easy installation
Post-sales support
Local, 24/7 service

Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

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