How to solve the dilemma of compressed air oil?
Compressed air is an essential component of modern industrial production and high-quality living. It is widely used in various industries around the world. With social progress and industrial development, more and more companies are paying attention to the quality of compressed air. In addition to requirements for compressed air flow, pressure, and power consumption, there are also different requirements for gas quality (dust, water, oil). During production, it is often found that liquid oil appears at the end of the workshop air supply, which poses a great safety hazard and seriously affects normal safety production, resulting in huge losses.
Compressed oil found in compressed air mainly comes from the lubrication system of the air compressor. The normal oil content in the exhaust of a screw air compressor should be ≤3ppm. If it exceeds 3ppm, it is considered as oil carryover, and in more severe cases, the air compressor may experience oil leakage. Regular addition of lubricating oil is necessary to reduce the amount of oil that runs to the back end of the air compressor, which can cause serious problems for the post-processing system, pipelines, drainage system, and end-use equipment. A small portion of the compressed oil also comes from the atmospheric environment. Oil exists in our atmosphere, and the higher the level of pollution in industrial areas, the higher the oil content in the environment. During the process of generating compressed air, various types of residual lubricating oil from the air compressor, pipelines, and valves are inevitably mixed in.
The hazards of excessive oil content in compressed air
The use of compressed air oil can have negative effects on the quality and lifespan of compressed air. Changing the conditions of post-processing can lead to subpar air quality, causing issues such as oil poisoning in the adsorbent of dryers and ultimately resulting in equipment failure. Additionally, the use of compressed air oil can accelerate corrosion and rust in pipelines and pneumatic components, affecting the precision and lifespan of pneumatic equipment. When compressed air comes into contact with products or semi-finished products, it can severely impact product quality and result in significant cost losses, particularly in industries such as food, pharmaceuticals, and semiconductors.
Cause Analysis of Air Compressor Flying Oil
To ensure the safe and stable operation of an air compressor, it is important to strengthen daily monitoring and maintenance, and promptly address any abnormal situations to avoid unnecessary losses. The main causes of oil spray from an air compressor are as follows:
- Air compressors are essential tools in many industries, but they can experience issues with their oil return systems. One common problem is a clogged or malfunctioning one-way valve, which can cause excess oil to flow back into the oil tank and then leak out of the compressor during operation. This issue is often seen in machines that lack oil circuit shut-off valves and one-way valves at the compressor’s exhaust outlet. To fix this, the valve should be inspected and cleaned of any debris, or replaced if damaged. Another issue can arise if the angled oil return pipe is installed too high or not inserted into the oil tank’s bottom gap, causing oil to accumulate and leak out with the compressed air. Adjusting the pipe’s height to 1-2mm above the bottom gap can solve this problem. Additionally, a flat oil return pipe that blocks the oil return port or a broken oil return pipe may also cause oil leakage and require replacement.
- An oil and gas separator can experience issues related to the oil component. These issues may arise from a failure to regularly replace the oil, using low-quality oil, or improper installation procedures such as puncturing the oil filter during installation of the return oil pipe. To prevent these issues, it is important to regularly replace the oil with high-quality, original equipment manufacturer (OEM) oil and follow proper installation procedures.
- There are two common issues related to engine oil: overfilling and selecting the wrong type of oil. Overfilling can lead to excessive oil consumption as some of the oil may be carried away by airflow. To avoid this, it is important to fill the oil to the correct level, which can be monitored through the oil level gauge. As for oil selection, it is recommended to choose high-quality oil that is suitable for your specific engine, based on the manufacturer’s guidelines.
- Issues with operating conditions can arise from two main factors. Firstly, if there is a significant drop in pressure, the flow rate may become too fast, leading to an increased oil load. Secondly, if the operating temperature is not maintained within the recommended range of 80-90 degrees, the oil content may increase as the temperature rises. It is important to monitor and maintain proper operating conditions to ensure optimal performance and longevity of the equipment.
Compressed air oil treatment method
The compressed air oil treatment method involves several steps to ensure that the air compressor does not release excessive amounts of oil into the air. Firstly, the source of the oil must be addressed to ensure that the oil content in the compressed air is within normal levels (≤3PPm). Secondly, post-processing equipment such as storage tanks, filters, and dryers must be regularly maintained to effectively remove any liquid water and oil. For industries that require low oil content, oil-free compressors can be used along with activated carbon filters or catalytic oxidation devices. Finally, reliable purification equipment should be installed to ensure that the compressed air is dry and clean enough to meet production requirements.
