Located on the doorstep of Cambridge Science Park and servicing multiple research labs working on ground-breaking projects - Cambs Compressors are accustomed to a challenge.
Air pollution, extreme temperatures, and their impact on compressed air
To design and supply a compressor kit which will operate at extreme temperatures and the most diverse atmospheric air quality standards. This was the challenge set by our client Levidian, a world leading climate tech business producing hydrogen and graphene through the decarbonisation of methane.
They work on pioneering projects and when they say extreme temperatures and challenging atmospheric conditions - we take them at their word. However, we were able to deliver a portable 'compressor kit solution' which met their requirements.
What does extreme temperature and air quality do to a compressed air system?
Extreme temperatures and air quality variations affect the efficiency, reliability and safety of a compressed air system. Here are some specific challenges we had to overcome in creating a solution for the project, plus the mitigation strategies. Although the specifics of the project are confidential, it will give you some idea of the complexities in designing the solution for this project.
The challenges of extreme temperatures on a compressed air system:
1 - Condensation: In cold temperatures, moisture in the compressed air can condense, leading to the formation of water droplets. This can cause issues such as corrosion, equipment damage and compromised air quality.
2 - Freezing: Extremely low temperatures can cause condensate to freeze within the compressed air system, leading to blockages and potential damage to valves, pipes and other components.
3 - Oil Viscosity: In cold temperatures, the viscosity of lubricating oil used in compressors may increase, affecting its flow and potentially leading to inadequate lubrication. This can result in increased wear and tear on compressor components.
4 -Material Performance: Extreme temperatures can affect the performance and integrity of materials used in the construction of compressed air system components, potentially leading to leaks or failures.
5 - Energy Efficiency: Cold temperatures can reduce the efficiency of compressed air systems, requiring more energy to maintain optimal operating conditions. This can lead to increased operational costs.
Instrumentation Accuracy: Instruments and sensors within the compressed air system may be affected by extreme temperatures, leading to inaccuracies in pressure, temperature, and other measurements.
The challenges of air quality on a compressed air system:
1 - Contaminant Levels: Air quality variations, such as high levels of dust, oil, or other contaminants, can impact the performance and lifespan of compressed air system components. Filters may clog more quickly, and the overall air quality may be compromised.
2 - Corrosion: Contaminants in the air, particularly moisture and corrosive particles, can lead to corrosion of the internal components of the compressed air system, reducing its lifespan and reliability.
3 - Oil Carryover: In systems where oil-lubricated compressors are used, maintaining low oil carryover is crucial for air quality. Contaminated air can negatively impact downstream processes and applications, especially in industries with strict air quality requirements.
4 - Microbial Growth: In humid conditions, there is a risk of microbial growth within the compressed air system. This can lead to issues such as fouling, blockages and compromised air quality.
5 - Filter Efficiency: High levels of contaminants in the air can reduce the effectiveness of filters, leading to more frequent replacements and potentially increased maintenance costs.
6 - Sensitive Processes: In applications where air quality is critical, such as laboratories, clean rooms, and certain manufacturing processes, variations in air quality can directly impact the quality and reliability of the final product.
Mitigation strategies to overcome the extreme temperatures and air quality variations
1 - Insulation: Insulating pipes and components in cold environments helps prevent condensation and freezing.
2 - Heating Systems: Installing heating systems or using heat exchangers can help maintain optimal temperatures within the compressed air system.
3 - Desiccant Dryers: Desiccant dryers can be used to remove moisture from compressed air, enhancing air quality and preventing condensation.
4 - Filtration Systems: Implementing effective filtration systems helps remove contaminants from the air, ensuring better air quality and protecting downstream equipment.
5 - Regular Maintenance: Conducting regular maintenance, including checking and replacing filters, monitoring lubricant quality and inspecting components, helps address potential issues before they become significant problems.
6 - Monitoring and Control: Implementing advanced monitoring and control systems allows for real-time tracking of system performance, enabling proactive responses to temperature and air quality variations.
7 - Climate-Controlled Enclosures: For outdoor installations, climate-controlled enclosures can provide protection against extreme temperatures, ensuring stable operating conditions for the compressed air system.