High exhaust temperature in an oil-free air compressor? Do you know the causes of these failures?
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High exhaust temperature is a common fault during the operation of air compressors. When a silent oil-free air compressor operates for extended periods in high-temperature environments, it accelerates the degradation of the lubricating oil, which severely affects the unit’s air output and service life. Excessive temperature rise can also cause high-temperature shutdown failures. There are many reasons for the excessively high exhaust temperature of air compressors, as follows: 1. Faulty temperature sensor. A failure of the temperature sensor can cause the PLC to give false readings of high temperature, leading to the shutdown of the unit. 2. Ambient temperature factors. The outlet temperature of the screw air compressor head is generally set at around 110°C, while the outlet temperature of the head equals the ambient temperature plus 60°C. The problem of excessive temperature in most silent oil-free air compressors is caused by poor environmental ventilation and heat dissipation. 3. Faulty temperature control valve. During the cold start of the compressor, the temperature control valve allows the oil to bypass the cooler and be directly injected into the compressor head, thereby accelerating the rise in oil temperature. To prevent dew formation inside the compressor, after it is operating normally, the ratio of oil flow through the cooler and the bypass can be adjusted based on the oil temperature, thereby controlling the injection oil temperature. If the temperature control valve is damaged or not functioning properly, a large amount of hot oil will flow directly into the main unit without passing through the cooler, resulting in high temperatures in the main unit.
4. Oil filter failure. Oil filters are used to remove dust and impurities from the oil circuit; they tend to get clogged after being in use for some time, which leads to poor oil return and consequently high temperatures in the main engine. 5. Fuel cut-off valve failure. The fuel cut-off valve controls its reciprocating motion for fuel injection via the pressure in the air tank; if a fault occurs that causes obstruction in the fuel circuit, this will lead to high fuel temperatures. Debris blocking the oil circuit or control air circuit can cause the fuel cut-off valve to close and prevent fuel from being delivered, which in turn can lead to high temperatures in the engine head due to insufficient or inadequate fuel for proper cooling. 6. Insufficient lubricating oil, a dirty or clogged cooler, can all cause excessive temperatures. 7. Faulty cooling fan, clogged cooler, increased exhaust resistance, resulting in poor heat dissipation and high temperatures. The dust on the outside and the oil stains inside the cooler should be cleaned.
Various problems within the air compressor system can cause the exhaust temperature of the oil-free air compressor to rise excessively. High exhaust temperatures lead to further malfunctions; in severe cases, it can even cause the main screw to get stuck or result in the shutdown of the machine, thereby disrupting the smooth progress of production. So, after ruling out these faults, are there any ways we can effectively prevent and alleviate the problem of excessive exhaust temperature in oil-free compressors during normal use? The waste heat recovery device for direct-heating shell-and-tube air compressors is specially modified based on the structure and principles of the compressors, in order to recover the heat energy that would otherwise be wasted and utilize it for domestic and industrial purposes.
Energy savings benefits: It has been proven that a 100HP screw compressor, when operating 24 hours a day, can have its waste heat recovered by an appropriate system, which in turn can supply hot water for 1,000 employees. The cost of such a system can be recouped within half a year. In the long term, besides providing hot water for the company’s employees, the waste heat recovery system can also be used for heating swimming pools, drying processes, and heating purposes. 2. In terms of other functions: (1) It helps enterprises comply with **energy-saving policies; there is no longer a need to use oil or electricity to heat cold water, which prevents energy waste and reduces pollution caused by the use of oil and electricity. It also lowers waste heat emissions, thus contributing to environmental protection. And it truly saves you astonishing amounts of money. (2) It facilitates heat dissipation of the air compressor, enabling it to operate properly. In the utilization of waste heat, the water heater absorbs most of the heat, keeping the operating temperature of the air compressor between 65 and 85 degrees. This allows the cooling fan to stop, thereby reducing electricity consumption as well as the problems associated with the aging of wire connections and the deterioration of lubricating oil. **It reduces the failure rate of air compressors, thereby ensuring a longer service life!
Great material; worth learning from.