The air compressor tank is a vital part of compressed air system.This article will explain why air compressor tank is important and how to size and maintain it.
Why air compressor tank is important?
The air compressor tank is also known as air tank or air receiver. In the compressed air system, we often see that the air compressor is equipped with an air tank at the rear end. So why does the air compressor need an air receiver? What is its main purpose?
There are many reasons why the air compressor is equipped with an air tank, which together ensure the stable operation, efficiency improvement and equipment protection of the compressed air system. The following are some main factors.
Balancing compressed air demand
The air compressor will continuously generate compressed air when it is working, but the consumption of compressed air is often not continuous, but has certain fluctuations. If this fluctuation is directly handled by the air compressor, it will cause its operation to be unstable and may even damage the equipment.
Therefore, installing an air compressor tank as a buffer device can effectively balance this air flow fluctuation and maintain a stable air pressure in the compressed air supply system.
When the amount of compressed air developed by air compressor is greater than the consumption of downstream system, the excess compressed air is stored in the air compressor tank; when the system workload increases and requires more compressed air, the air compressor tank will release the stored compressed air to meet the needs of the system.
For example the household air compressor that integrated an air receiver is the best air compressor for home garage. The balancing effect of air compressor tank ensures the stable operation and continuous air supply of the compressed air system.
Improve the stability of air system
Air receivers can not only balance compressed air demands and stabilize air pressure, but also act as pressure buffers for compressed air systems, reducing the impact of high-pressure airflow on precision pneumatic tools.
Installing an air receiver between the air compressor and air-using equipment or air dryers can make the air flow more stable, avoiding equipment damage or unstable operation caused by the impact of high-pressure airflow.
Especially for piston air compressors, Due to their structure, they usually have discontinuous exhaust, which can easily cause compressed air flow pulsation, possibly causing pipeline vibration and even damage to the pipeline network or parts.
Reciprocating piston air compressor
Reduce air compressor energy consumption
When the compressed air in air receiver reaches a certain amount, the air compressor will automatically enter the idling state. If the idling time exceeds a certain period (usually set to 300 seconds by air compressor manufacturers), it will automatically shut down, thus avoiding meaningless idling and excessive energy consumption.
This function is of great significance to the energy saving of air compressors. As we all know that air compressors consume lots of energy to operate, even the same to the most energy-saving VSD two stage air compressor.
(KED II Series 2-Stage Screw Air Compressor)
Extend air compressor lifespan
The air compressor consumes a lot of energy during the starting process, especially the current when the motor is started is much greater than the current during normal operation. Frequent starts and stops not only increase energy consumption, but also increase the wear and tear of the air compressor and shorten its life expectancy.
Installing air compressor tank can significantly reduce the number of starts and stops of compressor. When the system’s demand for compressed air fluctuates within a certain range, the air receiver can release or store gas to avoid frequent starts of the air compressor. This can not only reduce energy consumption, but also reduce wear and tear on the air compressor and extend the air compressor lifespan.
Purify and dry compressed air
The air receiver also helps remove moisture and pollutants from the compressed air and improves the air quality. In the air receiver tank, the high-temperature compressed air from the air compressor will stay for a while.
During this period, the compressed air collides with the wall of the air receiver tank and heat exchanges occur. The temperature of the compressed air decreases, and the impurities and moisture in it will condense and settle, and be discharged regularly or automatically through the drain valve or electric ball valve.
This can improve the quality of the compressed air discharged from the air receiver, reduce the impact of moisture and pollutants (tiny amount of lubricating oil) on subsequent equipment, such as the desiccant air dryers that always installed behind air compressor tank due to its desiccants will be damaged by lubricating oil in compressed air.
Cope with unexpected needs
In some cases, the gas consumption of the user’s gas-using equipment may suddenly increase. The air compressor tank can be used as a backup gas source in an emergency.
When the system needs additional gas supply, the compressed air in the air receiver can meet the short-term demand to ensure continuous operation or respond to emergencies.
If there is no air receiver as a buffer at this time, the air compressor may not be able to meet this sudden demand in time, resulting in production interruption or equipment failure.
The existence of the air compressor tank can ensure that there is enough compressed air available in case of sudden demand, thereby ensuring the continuity and stability of production. This is very important for some equipment and processes that require a stable gas source.
Security considerations
As a pressure vessel, the design and manufacturing of the air compressor tank follow strict safety standards. It can withstand changes in internal pressure and external impacts to a certain extent to ensure the safe operation of the air compressor system.
At the same time, air compressor gas tank manufacturers must also equip it with various safety accessories, such as pressure gauges, safety valves, etc., to monitor and control the pressure state of the system to prevent any dangerous situations such as over-pressure explosion.
In summary, the reasons for equipping air compressor tanks mainly include balancing and stabilizing air pressure, reducing energy consumption and extending the air compressors lifespan, improving the stability of air systems, cope with unexpected demands, and safety considerations.
These reasons together ensure the stable operation and efficient work of the air compressor system and improve the efficiency and life of the equipment.
How to select an air compressor tank？
In actual applications and when designing compressed air systems, it is usually considered to equip air tanks with corresponding capacity and appropriate pressure.
Users should choose the appropriate air tank model and specifications according to their own needs and conditions to ensure that the system achieves the best operating effect.
Types of air receiver tank
Common air compressor tanks include stainless steel air receiver tanks, carbon steel air receiver tanks and alloy stainless steel air tanks according to their manufacturing materials.
- Stainless steel air receiver tank: Made of stainless steel, it has good corrosion resistance and is suitable for occasions with high air quality requirements.
- Carbon steel stainless steel air receiver tank: The main structure may be carbon steel, and the interior may have a stainless steel lining or anti-corrosion treatment to improve corrosion resistance and durability.
- Alloy material stainless steel air receiver tank: Made of alloy materials (such as aluminum alloy, nickel-based alloy, etc.), it has special performance advantages, such as higher strength or better corrosion resistance.
How to size an air receiver tank?
Volume requirements
According to the air flow rate of air compressor: Generally speaking, the volume of the air receiver tank is 10%-20% of the air flow rate of the compressor, 15% is usually taken as a reference value.
If the gas consumption is large or the gas consumption fluctuates greatly, the volume of the gas tank should be appropriately increased to 20% or more; on the contrary, if the gas consumption is small and the fluctuation is not large, it can be lower than 15%, but it is best not to be lower than 10%.
For example, if the exhaust volume of the air compressor is 176.6 CFM, convert CFM to m3/min = 5 m3/min, then the volume of the air receiver is more suitable for 0.5 cubic meters to 1 cubic meter.
According to the gas consumption of pneumatic tools: For some scenarios with high requirements for gas continuity, such as automated production lines and tap water supply, it is necessary to consider that when the air compressor fails or is repaired, the gas volume of the air compressor tank should be able to maintain the normal operation of the gas-using equipment for a period of time.
In this case, the volume of the air receiver should be determined based on the gas consumption per unit time and the time required to maintain.
Pressure requirements
Match the air compressor pressure: The pressure of the air compressor tank must be greater than or equal to the working pressure of the air compressor. For example, a 10bar air compressor must be equipped with a 10bar or higher pressure air tank to ensure that the tank can store compressed air safely and stably.
Consider system pressure fluctuations: If there is a large pressure fluctuation in the system, learn how to calculate air pressure fluctuation range, then select an air receiver tank with a higher pressure rating to ensure that the tank can still work normally when the pressure fluctuates.
Air compressor tank maintenance
In industrial production, air compressor tanks are important equipment to ensure a stable supply of compressed air. In order to ensure its long-term reliable operation and extend its service life, proper maintenance is essential. The following will introduce some practical maintenance tips.
Check the safety valve
The safety valve is an important component to ensure the safe operation of the air receiver and should be checked and calibrated regularly. Ensure that the safety valve can open and close normally under the set pressure to prevent the air tank from rupturing due to excessive pressure.
It is generally recommended to calibrate the safety valve at least once a year, and the calibration work should be carried out by professionals.
Monitor pressure and temperature
Install pressure and temperature sensors to monitor pressure and temperature changes in the air compressor tank in real time. Abnormal pressure fluctuations or excessively high temperatures may indicate a system failure or potential danger.
For example, if the pressure suddenly rises, it may be due to a faulty intake valve or a blockage in the downstream gas-using equipment; while excessively high temperatures may be due to a failure of the cooling system or compressed air staying in the air receiver for too long.
Drain and clean regularly
Many users don’t know how to drain water from air compressor. Compressed air usually contains moisture, which will accumulate at the bottom of the air compressor tank. Drain the condensed water in the air receiver regularly to remove the accumulated impurities, oil and moisture to prevent moisture from corroding the air receiver.
Failure to clean the tank for a long time will lead to increased corrosion inside the compressor tank and affect the quality of the compressed air. The drain valve should be kept unobstructed and care should be taken to prevent compressed air leakage when draining.
Check the appearance regularly
Check the appearance of the air compressor tank regularly to see if there is any obvious corrosion, deformation or damage. Pay special attention to welds and joints, as these are prone to stress concentration and leakage problems.
If rust is found on the air tank surface, rust removal and anti-corrosion treatment should be carried out in time. For example, minor rust spots can be sanded and then coated with anti-rust paint, while serious corrosion areas may require repair welding or replacement of parts.
Lubricate and tighten parts
Check the connection parts and moving parts related to the air receiver, such as the valve stem of the valve, the bolts of the bracket, etc., to ensure that they are well lubricated, and tighten the loose parts in time. Proper lubrication can reduce wear and extend the service life of the parts; tightening parts can prevent failures caused by leakage and looseness.
Through the implementation of the above practical skills, the air compressor tank can be effectively maintained, its service life can be extended, the reliability and safety of the equipment can be improved, and a strong guarantee can be provided for the stable operation of industrial production.
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