Important information
Problem
The warm summer months are an especially difficult time for compressed-air systems that are susceptible to water contamination. Moisture entering compressed-air systems is the main contaminant that disrupts the operation of surface-treatment and spray-coating equipment. Water not only worsens the appearance of the treated products but also creates other less obvious problems, for example a deterioration of adhesion, which can manifest after some time. In addition, moisture can lead to frequent equipment downtime for cleaning or repair.
Examples of common problems
- Moisture in sandblasting equipment. Moisture leads to the formation of lumps in the material that clog the equipment and interrupt the air-flow supply. Disassembling and cleaning the equipment lead to lengthy downtime.
- Moisture in paint- and coating-application systems. Moisture usually has a higher density than the material and does not mix in the bulk phase, so it is the first to reach the surface being treated and leads to the formation of blisters and adhesion problems.
- Moisture in varnish and the clear coat layer during the processing of wood and furniture creates unattractive cloudiness and iridescence.
Solution
Unfortunately, it is impossible to beat the laws of nature. This means that in warm weather, if there is a source of moisture in the compressed-air lines, moisture will always condense. The warmer the air at the compressor inlet, the higher the probability of a large amount of moisture in the compressed and cooled air. Fortunately, Donaldson has developed products that make it possible to solve this problem.
Step 1. Cool the air. The simplest way to remove heat and most of the water from compressed air is to use a refrigeration dryer or heat exchanger.
Install the Donaldson DF filter housing with a coalescing element between the compressor or storage tank and the heat exchanger. Donaldson's coalescing elements provide protection against the sediment formed from compressor oils.
The standard DF filter housing
Step 2. Remove the condensate. When air is cooled in the lines, moisture forms. Donaldson M-series coalescing filters with proprietary Ultrapleat™ technology contain a special oleophobic and hydrophobic material with a much larger filtration surface compared with filters in the form of thread wound onto a tube.
The Ultrapleat element slows the air flow, which reduces the pressure drop and increases filtration efficiency.
The M-series Ultrapleat filter element
Step 3. Remove water in the gaseous state. Over-humidified air comes out of the refrigeration dryer. Subsequent cooling of such air leads to moisture condensation. To remove water vapors and lower the pressure dew point as much as possible, use the heatless adsorption dryer Donaldson Ultrapac™ Smart.
Ultrapac Smart is the ideal air-dryer option if a compact solution is required that is distinguished by high efficiency and low energy consumption.
To ensure optimal protection against moisture this summer, perform maintenance of the coalescing filter elements and the Ultrapac Smart dryer.
