Choosing the Right Post-Treatment Equipment丨Extend the Life of Your Air Equipment by 5 Years

Chanun air compressor

Post-Treatment Equipment

Air Receiver (Storage Tank)

Stores compressed air, buffers pressure fluctuations, and provides preliminary moisture separation (approximately 70% of liquid water deposits here).

An essential basic component for all compressed air systems.

Drying Equipment

Refrigerated Dryer

Cools compressed air to a dew point of 2-10°C via a refrigeration cycle, causing moisture to condense and separate.

Lower energy consumption, simple maintenance. Suitable for general industrial applications (e.g., machining, standard pneumatic tools).

Desiccant (Adsorption) Dryer

Utilizes adsorbents (e.g., activated alumina, molecular sieve) to deeply remove moisture, achieving dew points from -20°C to -70°C.

Heatless Regeneration: Regeneration gas consumption 12-16%. Simple structure, frequent switching.

Micro-Heat Regeneration: Regeneration gas consumption 6-8%. Requires an external heat source.

Blower Purge (Heated) Regeneration: Regeneration gas consumption 3-5%. Requires a blower and heat source.

Compression Heat Regeneration (Energy-Saving Preferred): Utilizes waste heat from the compressor, zero additional energy required. Requires a matched oil-free compressor.

Filtration System

Graded Configuration Principle (Must be installed sequentially in order):

P-Class (Pre-filter): Removes large particles (>3μm).

A-Class (Post-filter): Removes fine particles and oil aerosols (1μm).

F-Class (Fine filter): Highly efficient removal of oil and dust (0.01μm).

AC-Class (Activated Carbon filter): Removes oil vapor and odors.

AD-Class (Sterile filter): Microbiological filtration (dedicated for pharmaceutical/food).

Treatment capacity must match compressor discharge volume; filtration grade determined by final required air quality.

Selection Key Factors

Define Air Quality Requirements

Refer to international standard ISO 8573.1 and national standard GB/T 13277. Requirements vary significantly by industry:

General Industry: Satisfies Class 2-4 (Dew point > -20°C, Residual oil ≤1mg/m³).

Food/Pharmaceutical: Requires Class 1-2 (Dew point ≤ -40°C, Residual oil ≤0.01mg/m³).

Electronics/Semiconductor: Requires Class 0 oil-free standard (requires oil-free compressor).

Match Equipment Specifications

Discharge Volume (Capacity): Post-treatment equipment capacity must exceed the compressor's actual discharge volume; recommend 10-15% margin.

Working Pressure: Must match compressor rated pressure to avoid excessive pressure drop.

Temperature Compatibility: Inlet temperature directly affects drying efficiency; high-temperature environments require an aftercooler.

Energy Consumption & Economics

Refrigerated Dryer: Main power consumer is the refrigeration compressor.

Desiccant Dryer: Focus on regeneration gas consumption (5-18%) and heating power (0.5-0.9kW/m³/min).

Life Cycle Cost (LCC): Equipment price accounts for only ~30% of total cost; energy and maintenance costs account for ~70%.

Environmental Adaptability

Inlet Temperature: Requires pre-cooling if above 40°C.

Ambient Temperature: Affects refrigerated dryer efficiency (frost protection needed below 0°C).

Dust Content: High dust environments require a self-cleaning pre-filter.

Altitude: Compressor efficiency decreases ~5% per 1000m increase in altitude; post-treatment equipment needs corresponding adjustment.

Maintenance & Service

Filter Element Replacement Cycle: Typically every 4000-8000 hours under normal conditions.

Adsorbent Lifespan: Generally 2-5 years.

Drain Type: Zero-air-consumption electronic drains are preferred.

Choosing a reliable brand with a comprehensive after-sales service system is crucial.

System Leakage Issues (Affecting Output/Performance)

Rotor Clearance Leakage: Design clearances between screw compressor rotors and between rotors and housing. Seal teeth failure due to wear increases gas leakage.

Piston Component Wear: Severe wear of cylinders, pistons, and piston rings increases clearances and leakage, especially noticeable in equipment over ten years old. Wear on primary piston rings causes the most significant drop in discharge volume.

Valve Failure: Metal fragments lodged between or wear on suction/discharge valve plates and seats cause incomplete sealing and leakage. Improperly matched valve spring force also affects discharge volume – excessive force delays valve opening, insufficient force delays closing.

Cooling System Failure: Poor cooling increases body temperature, causing inlet gas to heat and expand, reducing actual intake volume. Leaks in intercoolers affect cooling and can cause gas contamination or moisture ingress.

Application Solutions

Basic Industrial Configuration (Machining, General Manufacturing)

Compressor → Air Receiver → Pre-filter (P) → Refrigerated Dryer → A-Class Filter

Dew Point Requirement: 2-10°C

Residual Oil: ≤1mg/m³

Typical Cost: Equipment investment accounts for 15-20% of total system cost.

Intermediate Purification Configuration (Automotive Painting, Precision Instruments)

Compressor → Air Receiver → Pre-filter (P) → Refrigerated Dryer → Micro-Heat Adsorption Dryer → F-Class + AC-Class Filters

Dew Point Requirement: -20°C to -40°C

Residual Oil: ≤0.01mg/m³

Key Point: Need to control regeneration gas loss.

High Purity Oil-Free System (Food/Pharmaceutical, Electronics/Semiconductors)

Oil-Free Compressor → Air Receiver → Precision Filter → Compression Heat Adsorption Dryer → AD-Class Sterile Filter

Dew Point Requirement: ≤-40°C

Residual Oil: ≤0.001mg/m³

Certification Requirements: Must comply with FDA, GMP, etc.

Energy Efficiency Priority Solution (Large Factories with Continuous Operation)

Centrifugal Compressor → Large Air Receiver → Waste Heat Regeneration Adsorption Dryer → Three-Stage Filtration System

Energy Saving Feature: Utilizes compressor waste heat for regeneration, zero additional energy consumption.

Return on Investment (ROI): Recovers incremental investment in 1-3 years.