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Air compressor aftercoolers

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Michael Johnson

10-28-2000 04:11:02




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I am trying to find out where is the best place to install an aftercooler (water) on my air compressor system. I belive that it should logical be install between the pump head and the tank so you would be able to cool the air leaving the compressor head and thererfore extract the water out of the air before you store it in the tank. Also, by doing this, you should increase your overall volume of air that goes it to the tank because it is cooler. I belive that doing it this way will prolong the life of the tank because you do not have all that water sitting in the bottom of it.
All the layouts I have ever seen show the air coming directly from the compressor into the tank. Perhaps this is just for simplicity?? A factory thing??
Any ideas?? Thoughts??

Thanks,
Mike

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Franz

10-29-2000 00:42:20




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 Re: Air compressor aftercoolers in reply to Michael Johnson, 10-28-2000 04:11:02  
The most effective place to remove maximum water is between the compressor and the tank. You can build an effective seperator from 3 feet of 2" pipe, and a few fittings. It is best to connect the seperator to the compressor and tank with flex lines. A reverse acting solonoid valve will purge the water from the seperator when the compressor stops running. _||_< Air out to tank |```| |```| |```| _|_``| air in _ _ || < weld elbo into pipe at 18" |`||| Incoming air turns down |~~~| |~~~| |~~~| |~~~| ^ water out This system works best with 1/2" air lines and water connection sized to outlet valve. It will also work at point of air use, but doesn't remove as much water. The unit must be vertical, and if additional cooling is needed, you can wrap the housing with a water jacket, or wind a coil of 3/8 copper for water to flow thru. Black iron pipe works best.

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Roger Prosper

10-28-2000 16:59:50




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 Re: Air compressor aftercoolers in reply to Michael Johnson, 10-28-2000 04:11:02  
Installing the air output of the compressor directly through the aftercooler is a bad idea, since the vibration of the pump will likely break the pipe joints on the cooler, unless you use something like steel-braided teflon hose. Put a good electronic auto drain on your tank, and use the aftercooler to chill the air as it leaves the tank and goes into your system. Put a particulate filter and coalescing filter in the pipe line after the cooler, and remember to install valves before and after the filters so you can isolate them for changing, without having to blow down the entire system. You can put float type auto drains on the filters to take car of any water that accumulates in the bowls, but, again, I would prefer electronic units. Any drier air will require an air dryer.

I hope there are automatic valves to control the water supply through the aftercooler, as it will get very expensive to run water through it continuously. I have seen many industrial applications bypassing their water type aftercoolers for just this reason.

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Michael Az

10-28-2000 08:08:24




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 Re: Air compressor aftercoolers in reply to Michael Johnson, 10-28-2000 04:11:02  
third party image

Michael, here is a pic of the system I put in my shop and it removes all the water even though the air feeds from the compressor to the tank. The top line [exhaust] goes down the wall 25' with outlets and traps at the end and then comes back. The 50' does a pretty good job cooling and condensing the air. The toilet paper filter on top is brought on line for painting. ----- -----Michael

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ltf in nc

10-28-2000 07:42:05




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 Re: Air compressor aftercoolers in reply to Michael Johnson, 10-28-2000 04:11:02  
To achieve the optimum results the cooler needs to be mounted where it can efficiently cool the compressed air to the maximum and hopefully below ambient. This will ring out the most moisture. Ideally, this will be after the compressor and before the receiver tank. In an intermittent use application, the air will warm in the supply line and the moisture will be expanded in that air and become less of a nuisance. If near the point of consumption, the compressed air is permitted to cool lower than the temperature reached in the aftercooler addition condensation will occur and that moisture will have to be addressed. This is best handled by a refrigerant air dryer. I do not like dessicant units due to the maintenace and potential to malfunction. In a small shop the layout of the supply lines and the manner in which the pipes are run can minimize problems and reduce the dependence of additional equipment.

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