The right inline air compressor filter solution - Atlas Copco Ireland

Particulates: Particulates in compressed air are small pieces of material like dust, dirt, and/or pollen, as well as loose metal pieces. Depending on the sensitivity of your application and or process, contact with particles can be damaging to the end product. They can also cause delays in production and quality control issues, as well as unsatisfied customers.

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Aerosols: Aerosols consist of small droplets of liquid found within a compressed air system, especially in oil-injected machines. Aerosols are created from lubricant. Therefore, oil used in the compressor can be harmful to both products and people if not treated properly.

Vapors: In a compressed air system, vapors consist of lubricants as well as any other liquid that has converted to a gas. Such vapors require a special carbon activated filter in order to be removed from the system.

Now that we have a better understanding of the contaminants above, let us take a look at what types of filtration methods are used.

There are three main mechanisms utilized in dry particulate filters to remove solid particles from compressed air. These three forces contribute to the overall efficiency of the filter.

Inertial Impaction: Inertial impaction is a process where particles that are too heavy to flow with the compressed air stream get trapped in the fiber media of compressed air. The larger the particles are, the easier it will be to separate them.

Interception: Smaller particles can follow the air stream. However, if the diameter of a particle is larger than the gap of the filter media, it will get caught by the filter media. This makes it easier to eliminate larger particles than smaller ones.

Diffusion: Diffusion happens when small particles move erratically throughout the surface, instead of following the compressed air stream. This irregular movement path is caused by the particles colliding with other gas particles, an occurrence called Brownian movement. Since the particles have a free-range of motion, it is more likely that they become intercepted and removed by the filter media. Through diffusion, separation of smaller particles is easier than separating larger ones. 

Two types of filters are used to remove aerosols and vapor. Coalescing filters are utilized to remove liquids as well as some particulates, while vapor filters use adsorption to remove vapors from compressed air.

Coalescing: Coalescing filters are used to remove aerosols and particulates, but are not effective in the removal of vapors. The coalescing process consists of bringing small droplets of liquid together in order to form large droplets. As the droplets increase in size, they fall from the filter into a moisture trap, resulting in a cleaner and dryer compressed air stream.

Adsorption: Adsorption is a chemical process used to remove gaseous lubricants or vapors. This process involves vapors bonding with the surface of the media (adsorbent). Activated charcoal filters are commonly used since they attract oil vapor.

As the oil vapor covers the surface of the activated charcoal over time, it is essential to change the filter before it becomes saturated. If not, this would lead to a breakthrough of the oil into the air system.

It is also necessary to use a dust filter after the activated charcoal filter. This is because small charcoal particles could break out and enter the air stream.

To assess the potential damage oil can cause to your compressed air system, it's important to understand your equipment and basic industry requirements. If your industry has strict health codes and or your equipment is sensitive to oil / vapor exposure, it is crucial to use proper filtration.

Let’s take a closer look at lubricants and understand the effects they can have on your end product. Similar to particulates,lubricants can enter your compressed air system from ambient air as well as from the compressor itself. Facility operations, like a motor exhaust, release hydrocarbons like oil aerosols into the ambient air, which can compromise air quality and cause equipment failure.

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Oil injected air compressors will also release lubricants into the compressed air system, resulting in increased operational and maintenance costs. Industries such as electronics and semiconductor are especially exposed to lubricant contamination, which can result in product loss, missed deadlines and unsatisfied customers.

Just wondering what sizes of compressors are you guys using and your air filter/water separators have you guys been having success with?

I have a 33 gallon air compressor and was hoping that would be large enough to start out with but still need to purchase a air filter/water separators and don’t know what is a good product for specifically plasma cutting. I will be using the Vipercut 30 and eventually will probably purchase a Hypertherm 45.

Its more the output of your compressor vs size. A smaller compressor is going to run more and limit you to shorter cuts (there seems to be many users using a 30 gallon compressor with no issues), but you need to pay attention to the CFM’s…

The Vipercut 30 requires 6 cfms at 55-75 PSI.

The Hyperterm 45 requires 6 cfms at 90 PSI.

You’ll want to make sure that whichever cutter you go with your compressor can, at a minimum, meet those specs.

My set up a 60 gallon Husky compressor, Hypertherm 45 and multiple drop lines and filters for moisture control. I started with the Razorweld 45. I used it once and switched the the Hypertherm. If you plan on eventually going that route just buy the Hypertherm and be done with it, you wont regret it.

I run a Motorguard M26 filter right before the Plasma. The M26 and M60 is a filter made for Plasma cutting systems and works great. I am running a Eastwood QST-30/60 Scroll compressor with a air cooler of over 50’ with 3 drip legs then a water/separator/filter then copper lines around the shop with a 12" drip leg at every connection point and then the M26 right before the hose to the Plasma and I have zero moisture issues. Not a cheap setup but a trouble free system for Plasma and a Blast cabinet and powder coating.

http://motorguard.com/air_2_6.html

I have what looks just like jamesdhatch has except i also have 2 more with filters and water separaters with drains that are all hooked together in one nice mountable peice. was like 105 bucks on ebay i think. And the one on the plasma cutter also. I leave the drain on compressor seep all the time. Damp and and cold here and no issues yet. https://www.ebay.com/itm/1-2-COMPRESSED-AIR-INLINE-FILTER-DESICCANT-DRYER-3-STAGE-GOOD-FOR-PLASMA-CUTTER/?hash=item3ab6a91d11

I’ve found (the hard way) that it’s much better to dry the air all you can BEFORE it is stored in the tank. I live by the beach, and humidity was often a problem. Without an inline dryer my paint guns would always sputter and the plasma cutter had issues. My compressor before modifying would get LOTS of water into the tank which isnt good for either the tank or your tools, and a separator after the regulator didn’t stop moisture in the lines. I drained a much higher volume of water from the tank than from the separator.

What fixed it was to mount a four pass oil cooler after the compressor but before the tank. The lower line of the cooler goes to the inlet of a filter/separator which captures the water before the air goes into the tank. I now get next to zero water from the tank drain, but have to keep up with the filter drain.
Behind the cooler is a pair of large flat 120V “muffin” fans which run when the compressor is on.
I still keep the Motorguard M26 filter at the plasma cutter, but now the elements seem to last forever.

I have the opportunity to get a 140 gallon tank for free(was a propane tank in its earlier life). I presently have a 30 gallon air compressor/tank combo. I thought it might make sense to get another air compressor pump for the 140 gallon tank from Harbor Freight. Is 140 gallons overkill? If it wasn’t free I would not consider getting more than a 60 gallon air compressor/tank combo for the Crossfire Pro I will be getting in April. I can get a 5 hp air compressor pump from Harbor freight for $132 after 20% discount. Seems like it is worth it. The pump I’m considering has user reviews that say they fill two 60 gallon tanks without strain. Pump specifications say that it delivers 17.3 CFM @ 40 PSI and 15.2 CPM @ 90 PSI. Any advice or comments would be appreciated.

I would be weary of that pump from HF, if it is not a 2 stage compressor then it most likely not made to build pressure much past 90 lbs. My plasma cutter cuts best at 85 lbs, there is not enough room there for comfort. 140 lb would serve you better, that tank is ideal though with the right compressor. Let’s face it, you spent alot of money on that crossfire pro, I would use the compressor you have now untill you can get a 5hp, 2 stage, compressor pump that will last you many years. just my 2 cents

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