Summer is here, and it’s a hot one.
While businesses cannot control the summer heat, they can effectively manage how their compressed air systems operate under these conditions.
Ensuring optimal air compressor performance, especially in industrial settings, requires understanding the effects of high temperatures and implementing strategic measures to combat them.
Businesses operating in high-temperature environments must prioritize effective heat management and cooling strategies to maintain system stability and operational costs.
Optimizing compressed air systems for high temperatures starts with the design and installation.
Equipment design and installation can directly impact your compressor’s ability to operate in high ambient air temperatures. If space allows, it is best practice to install your system in a well-ventilated area where there is a minimal risk of ambient temperatures increasing the heat generated by the compressor itself. There should be at least three feet between the industrial compressed air system and walls, obstructions, or other equipment. Ample space around the compressor allows for better air circulation and helps prevent hot air from being recirculated into the system.
We understand that indoor installation isn’t always possible. In situations where space constraints make it less feasible to place your compressed air system inside, there are customizable solutions to provide reliable compressed air into your facility from the outside in a protective environment. At Air Handling Equipment, we offer a solution called Compressed Air Pods. This innovative solution provides reliable compressed air to your facility without compromising valuable production space. Our compressed air pods include pre-plumbed compressed air systems with proper ducting for effective ventilation through all months of the year.
How an undersized air compressor can negatively affect your operations and energy efficiency
Just as important as where you place your compressed air system, properly sizing your compressed air system is critical. When choosing the right size, always consider your current compressed air demand and your plans for future growth. Sizing a compressed air system for today’s needs may be too small for the workload in 1-3 years. An undersized compressor, dryer, filters, tanks, etc. can cause several issues from drops in pressure to passing moisture downstream.
Choosing a compressor size and model that effectively meets your workload requirements will help prevent issues of inadequate compressed air supply.
To avoid selecting an undersized compressor, consider the following guidelines:
1. Assess Air Demand
Evaluate the total air demand of your operation’s tools, machines, and processes. Identify each tool’s required Cubic Feet per Minute (CFM) at a specific operating pressure (measured in Pounds per Square Inch or PSI). Check the manufacturer’s specifications if you aren’t sure how to calculate the required pressure or flow rates. Add the demands to determine your total PSI requirements.
2. Factor in Duty Cycle
Duty cycle refers to the duration an air compressor runs compared to its rest period within a cycle. To prevent overworking the system, select a compressor with an adequate duty cycle to match or exceed your operational requirements.
3. Consider Future Expansion
Anticipate future growth and additional demand on your compressed air system. Opt for a unit that meets current requirements and offers room for increased capacity.
4. Evaluate Air Quality Needs
Different applications require varying levels of air purity. When considering a new compressed air system, make sure to consult with the right contacts at your company and our team at Air Handling Equipment about required compressed air standards for your production.
5. Contact Air Handling Equipment Specialists
With so many factors affecting the quality and function of systems, selecting equipment that can do the job and do it right can be overwhelming. We’ve been in the business for almost fifty years and can provide equipment recommendations to minimize downtime and maximize efficiency.
Keeping your air compressor cool will help prevent uninterrupted operation.
Air compressors generate heat as they compress air, and heat can accumulate rapidly in high-temperature environments. The hotter the air, the harder your compressor has to work to compress it. Excessive heat can lead to overheating, reduced efficiency, and even equipment failure, causing expensive production downtimes and repairs. As a general rule, industrial air compressors should operate in room temperatures between 50 and 85° Fahrenheit to prevent freezing or overheating.
Along with temperature control, businesses can enhance compressor performance by monitoring or adding the following parts and accessories within their systems:
Air Intake Filters: Dirt and contaminants can clog air intake filters, causing the compressor to work harder to draw in air. Regularly replacing intake filters, especially with high-efficiency options, is a simple and effective way to keep temperatures down and performance up.
Aftercoolers: Aftercoolers are heat exchangers that cool the air discharged from the compressor before it enters the air receiver tank or piping. Typically, most cool the air to within 15-20 degrees Fahrenheit of the ambient temperature.
Air-cooling: Air-cooling utilizes ambient air to cool the compressor. Fans, cooling fins, or other airflow mechanisms dissipate heat from the compressor unit. Fins are often attached to the compressor’s cylinders and sometimes to the aftercooler, increasing the surface area over which cooling can occur. Air is blown over the surface of the compressor where the heat exchange occurs, carrying away the heat with it.
Water-cooling: Water-cooling systems use water to remove excess heat from the air compressor. Cool water circulates the compressor’s cylinders or jacket, absorbing the heat generated by the compression process. The heated water is then cycled through a cooling unit to dissipate the heat before being recirculated. Water cooling is particularly effective for high-capacity or industrial air compressors. Chillers are a good example of systems designed to transfer heat through circulating cooling water.
At Air Handling Equipment, we offer Gardner Denver and Thermal Precision brands of chillers and fluid coolers with specifications like:
- Dry bulb fluid cooling for energy efficient 80-105 degrees F water packages
- Chiller packages for 40-70 degrees F systems
- .6 to 100 ton chiller packages
- Larger engineered packages
Proper lubrication ensures the ongoing efficiency and longevity of your compressor.
Heat can cause oil and lubricants to break down faster. High temperatures thin out lubricants, reduce their effectiveness and increase the risk of wear and tear on your compressor.
Using lubricants formulated specifically for high-temperature conditions can mitigate these risks. We recommend using high-quality, synthetic lubricants designed to withstand elevated temperatures. Synthetic compressor oils generally have a higher boiling point and better thermal stability than standard oils, making them ideal for industrial use in hotter climates. A rule of thumb to consider, normal operating temperatures should be 180 degrees Fahrenheit. Any temperatures 200+ decrease the effective life of the oil in the compressor by half. That oil life continues to be cut in half every 10 degrees Fahrenheit thereafter (i.e., 200, 210, 220, 230 degrees Fahrenheit will cut 8,000 hour oil to 4,000, 2,000, 1,000, 500, 250 hours).
Consistent checks and maintenance can help identify and prevent many heat-related issues.
A well-maintained air compressor is better equipped to handle high temperatures. We recommend scheduling yearly maintenance agreements with professionals like Air Handling Equipment. However, you can also perform checks between scheduled visits. Check for leaks in the cooling system, ensure that aftercoolers are free from obstructions, and confirm that lubricant is at the appropriate level and condition for operation.
A preventative maintenance schedule will prolong the quality and life of equipment, regardless of ambient temperatures. Adopting a proactive approach to managing your industrial air compressors in high-temperature environments protects your investment and ensures continuous, efficient operation.
The Risks of an Overheated Air Compressor
Without cooling solutions in place, high-temperature conditions can cause:
- Increased energy consumption and operational costs due to inefficiency.
- Accelerated wear on compressor parts, leading to more frequent repairs or replacements.
- Irregular duty cycles, leading to frequent starts and stops that further strain the system.
- Risk of fire or explosion in extreme cases due to overheated components.
- Contaminated air supply, compromising product quality or safety in sensitive applications.
With Air Handling Equipment, businesses can ensure their air compressors run efficiently, even in the most demanding high-temperature environments.
Don’t let the heat beat your compressed air systems. We are dedicated to providing our clients with tailor-made solutions that meet the unique challenges of their operational climate. Contact Air Handling Equipment today to ensure your compressed air systems are equipped to handle high ambient temperatures.
With office locations in Sidney, Loveland, and Gahanna, Air Handling Equipment has provided compressed air system solutions to the Midwestern and Southern Ohio markets since 1977. This includes proudly serving the greater Cincinnati, Columbus, Dayton, Lima, and Findlay, Ohio areas. For questions about our selection of used air compressors, call one of our locations or fill out our online contact form, and someone from our team will get back to you as soon as possible.
