Lubricant contamination is a pervasive issue, with over 70% of equipment failures attributed to it. As a leading air compressor OEM emphasizes, particulate contamination, especially ultra-fine solid particles under 10 microns, poses a significant threat to air compressors. These minute particles, present even in new oils, wreak havoc on compressor reliability, leading to escalated maintenance and repair costs.
The Menace of Ultra-Fine Solids:
While all solid contaminants in compressor oils are problematic, ultra-fine particles, often labeled as “clearance-size,” are particularly destructive. Typically measuring less than 10 microns, these particles evade effective removal by the compressor’s standard inlet air and oil filters, accumulating in the oil and causing disruptions to lubrication, increased friction, wear, fouling and damage to critical compressor internals.
Consequences of Neglect:
Ignoring these ultra-fine solids accelerates the wear of air-end bearings and shaft seals, simultaneously clogging air-oil separators, oil coolers, and injection lines. This domino effect leads to elevated operating temperatures, faster oil degradation, reduced oil and separator life, increased energy consumption, and heightened maintenance costs – a considerable burden on your compressor and budget.
Inadequacy of Standard Air Compressor Oil Filters:
Rotary screw air compressors share an inherent vulnerability to ultra-fine solid contamination due to their design, making them prone to vacuuming up these particles. Unfortunately, standard inlet air filters, rated based on dust holding capacity and pressure drop, often fall short in providing effective protection. The OEMs’ undisclosed filtration efficiency for specific particle sizes leaves room for ultra-fine contaminants to pass through in many industrial settings.
Challenges in Air Compressor Oil Filtration Enhancement:
Enhancing inlet air filtration to counter ultra-fine solids is a logical solution, but it comes with challenges. The delicate balance between filtration efficiency and pressure drop affects compressor performance. Compressor manufacturers face the dilemma of avoiding oversized inlet air filters that could compromise performance and increase costs, making them less competitive.
Insufficiency of Oil Filters:
With inlet air filters unable to halt ultra-fine solids, the responsibility falls on the compressor’s oil filter. However, standard OEM oil filters, typically rated for 10 microns nominal or 20 microns absolute, provide only minimal protection. A 20-micron absolute oil filter, comparable to a household coffee filter, does little to safeguard compressor bearings, limit wear, or extend bearing and air-end life.
A Revolutionary Solution – Compressor Oil Purifier:
Enter Fluid Metrics’ Compressor Oil Purifier (COP), a game-changing solution tailored for oil-injected rotary screw air compressors. The COP, functioning as a low-flow “bypass” device, complements the standard oil filter by continuously removing ultra-fine solids that the latter can’t address.
Unveiling the COP Advantages:
The COP boasts proprietary purification elements, combining ultra-fine filtration (down to 3 microns absolute) with ion exchange media to eliminate acids, dissolved solids, and varnish precursors. ISO Particle count testing reveals the COP’s ability to maintain compressor oils over 30 times cleaner than standard 20-micron absolute oil filters and twice as clean as brand-new oil.
Benefits of Choosing COP:
- Reduced Bearing & Seal Wear / Increased Air-end life
- Reduced Separator Fouling & Pressure Drop / Increased Separator life
- Reduced Energy Consumption / Lower Electrical Costs
- Reduced Oil Oxidation – Degradation / Increased Oil Service Life
- Increased Protection & Compressor Reliability
- Reduced Compressor Maintenance, Repairs & Downtime
- Reduced Oil and Separator Consumption / Change frequency / Waste Disposal
- Reduced Environmental Impact / Improved Sustainability
- Reduced Cost of Ownership
When compressor reliability, maintenance costs, and environmental impact are critical, the Compressor Oil Purifier emerges as a proactive solution. Contact us today to discover how the COP can significantly benefit your air compressor system.