Compressed Air Dryer Filter And Accessories

It removes aerosols of liquids such as water and oil by coalescing. Coalescing is the process of capturing smaller droplets along a filtration medium. This is until they combine into larger droplets.

The droplets continue to coalesce until their weight is large enough. Finally, under gravity, they fall to the bottom of the air compressor water separator filter. Then they are discharged by the drainer.

Filter life and dirt-holding capacity are limited. Therefore, compressed air quality cannot be guaranteed when its life expires. Usually, the replacement cycle of our filter element is 8000 hours.

In addition, it is not only to ensure air quality but also to consider pressure loss and energy consumption. The additional power of the air compressor must compensate for the pressure loss of the filtration system. As a result, the power consumption of the compressor increases. Eventually, operating costs and expenses will rise. Now take two examples for comparison.

Example:

Electricity fee: 0.07USD/kWh,

For every 100SCFM air consumption, the pressure loss will increase by 1PSIG,

Finally annual increase in electricity bills due to pressure loss: 67 USD.

In conclusion, in case 2, the filter element was used twice as long as in case 1. However, the total cost increased by $940 due to a bigger pressure loss. So much more than the cost of replacing the filter element ($400). Thus, we must exchange the air compressor water separator filter element in time.

Firstly, this gauge is not a service indicator for the air compressor water separator. Besides, it is also not an indicator of air quality either. It just shows the differential pressure roughly. Or indicate whether the filter element is blocking in advance.

Filter fibers gradually become brittle during use. So even a tiny hole can cause the filter media to break. Then contaminants will enter the downstream compressed air system without filtration.

In this case, the pressure difference between the front and rear of the compressed air filter is not large. So the pointer will always be in the green area.

So the filter element will not be replaced in time. And when we find there are already a lot of pollutants downstream.

Generally, filters only remove solid and liquid particles. However, water vapor and oil vapor can still pass the filter material. Therefore, the mechanical filter cannot filter them out. Of course, except for the activated carbon compressed air filter.

To fundamentally remove water vapor and oil vapor, only use a dryer to lower the dew point.

Many people mistakenly believe that it is enough to choose a high-precision filter. This saves costs. This is not correct.

Air quality depends on the accuracy of a single filter. But without the pretreatment protection of the pre-stage filter, the high-precision filter element will be blocked soon due to excessive load.

So it will speed up the replacement frequency of the filter element. Finally, it will increase the production cost in a disguised form.

In some industrial situations, there is often inhalation of dangerous air, liquids, or particles. To protect our workers, filtering is necessary.

For example, carbon monoxide is a toxic gas. If without filtration, it will be a hazard to our workers. A breathable compressed air dryer filter can remove these harmful gases. It can convert carbon monoxide into carbon dioxide.

Compressed air has more and more wide applications in industry. At the same time, the quality requirements for compressed air are getting higher and higher.

The air will contain many impurities, such as bacteria and dust. Some industries require it to be sterile-filtered. Otherwise, it will affect the production of the enterprise. It will also increase the consumption of resources and funds.

We can produce quick-fit stainless steel compressed air sterilizing filters. These sanitary filters are popular in industries such as beer, dairy, pharmaceutical, beverage, food, etc.

Unlike general air compressor water separator filters, its housing is 304 stainless steel. Besides, the filter element is not a filter paper material but PTFE.

It sterilizes the air with high-temperature steam. The sterilization efficiency can reach 100%. The time is about 20 to 30 minutes.

Filtration accuracy refers to the max size of particles that the element can block. The higher the filtration precision, the smaller the particle size blocked.

But it is also easier to be blocked by particles with larger sizes. Therefore, using high-precision filters regardless of the occasion cannot guarantee improving filtration efficiency. Besides, it will affect the service life.

The largest contaminant in compressed air is water. Water includes liquid water and moisture vapor.

Air compressor water separator filter can remove liquid water. But it cannot remove moisture vapor. Besides, as the temperature decreases, the latter condenses into liquid water.

So this brings great trouble to the downstream pneumatic equipment. Water vapor can only be removed with the air compressor dryer. Therefore, a compressed air filter cannot replace it.

Refrigerant air dryer has rated requirements for inlet air temperature and pressure. In addition, the refrigerant dryer also requires that there is no liquid water in the air. So it can avoid increasing the refrigeration load.

This requires a pre-filter or air-water separator. The requirements for air compressor air dryer filter precision are not very high. Our pre-filters have a filtration precision of 1.0 μm.

The dust particles in the air do not significantly affect the cooling capacity. Water vapor requires the involvement of particles in the condensation process. Besides, the condensation water with larger sizes is easier to separate than the smaller ones. Finally, all these solid particles will be discharged with the condensate.

This reflects that the refrigeration air dryer itself has a self-cleaning function. So there is no point in having an air compressor water separator filter with too high a precision before the refrigerated dryer.

Firstly, desiccant dryers have higher filter requirements than refrigerant dryers. Because the adsorbent is very sensitive to oil. The oil vapor content should be under 0.1mg/m³. Otherwise, it will influence the water-removal effect of the adsorbent. Besides, it will shorten the lifetime.

Secondly, the adsorption dryer should have a dust-removal compressed air filter. The filtration precision is 0.01 microns. Because of the constant friction between the adsorbent particles, it will generate dust. Then this dust will enter the downstream air pipe. Eventually, it will cause secondary air pollution. So there must be a high-precision filter.

Pressure drop is an important indicator of an air compressor water separator. In addition, it can also measure the working life of a filter element.

Firstly, the filter element has a tiny initial pressure drop. But with time accumulation, the pressure drop will tend to rise.

When reaching a certain value, the lifetime of the filter element ends. At this time, it should replace the element.

To observe in time, we should add a differential pressure gauge. It can show the pressure drop of the compressed air filter at any time.

The housing is an important part of the air compressor water separator. It withstands the full internal pressure. Therefore, the filter housing must have high tensile and compressive strength.

In addition, the working conditions of air compressor dryer filters are generally harsh. The inner wall of the filter housing is often in contact with the oil-water mixture. Thus, it should have an anti-rust and anti-corrosion ability.

They are different. The compressor filters are used for the screw air compressor. And it includes there kinds of filters. That is the intake air filter, oil filter, and air-oil separator.

But the compressed air dryer filter belongs to the air treatment equipment. And we usually install them onto the main pipe. These filters work with dryers to purify compressed air. Because the air compressor water separator filter can remove dust, moisture, and oil vapors.

Firstly, activated carbon has a huge surface area. So it has a strong physical adsorption ability. And it can adsorb chemical impurities such as organic vapors, sulfur, carbon dioxide, and various micro-organisms.

Therefore, it is widely used for oil removal and deodorization applications. Or we also use it as a sterilization filter. Oil vapors can easily pass through coalescing filters. So we need this carbon filter.

The main function of an activated carbon compressed air filter is to remove oil and hydrocarbon vapors. They are most commonly used where removing taste or odor is critical. For example, food processing and pharmaceuticals.

Since moist air reduces activated carbon adsorption, generally install it after the desiccant dryer. In addition, activated carbon filters can’t remove liquid oils or sols. So poor maintenance or no pre-filter will accelerate its performance failure.

There is a float drainage system in the automatic drain. When the pressure is low, the drain is closed. So it will not carry out drainage work at this time.

However, when the buoyancy and pressure are in balance, it starts to drain in drips. When the buoyancy force is greater, the drain port will open. Then it carries out drainage. So it works cyclically according to the buoyancy force.

The pre-filter is also namely the rough/coarse filter. In most cases, it is used at the front end of the pipeline. Therefore, we call it the compressed air pre-filter.

The main function is preliminary compressed air filtering, such as oil, moisture, dust, and rust. It can protect the fine filters downstream. To prevent large impurities from damaging the precision filter.

On the contrary, the post-filter mainly refers to high-precision filters. Its filtration accuracy will be much higher. Besides, we usually install it at the back end of the pipeline.

There are many reasons for air leakage, such as the automatic drain or drain valve leaking, poor closure of the filter end cap, or filter housing leakage. So the troubleshooting is as follows:

1. Close the drainer well; clean up impurities in time; or replace a new automatic drain;
2. Contact the compressed air filter manufacturer to exchange a new end cap or housing.

• Working medium: general compressed air.
• Nominal flow rate: 1.5 to 22m³/min (thread connection);
• 28.5~170m³/min (flange connection);
• Maximum nominal pressure: Max 16 bar (25bar & 40bar customizable);
• Pressure drop or loss: 0.2~0.25bar;
• Operating temperature: up to 80°C;
• Filtration accuracy: 5μm, 1μm, 0.01μm;
• Connection: thread and flange connection;
• Filter element material: HV glass fiber filter material.
• Casing material: die-cast aluminum alloy, carbon steel, and stainless steel available.