Compressed air is essential in numerous industrial processes, acting as a safe, reliable, and flexible power source. It serves as the lifeblood of operations, facilitating the functioning of tools, machinery, and automated systems. However, some applications demand high-pressure air beyond the capabilities of standard systems.
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This is where compressed air boosters enter the scene. These devices amplify the pressure of air and gas inputs to meet the specific requirements of high-pressure applications.
By providing a &#;boost&#; to standard compressors, air boosters ensure that the demands of high-pressure applications are met without the need for complete system overhauls.
A compressed air booster, often referred to as a pressure multiplier, is a device designed to increase the output pressure (typical max pressure: 100 bar) of the air supplied by a primary, or existing air compressor (typical max pressure: 13 bar).
It operates as a high-pressure compressor within the confines of a closed system, taking in air at one pressure and outputting it at a significantly elevated pressure. The booster achieves this through a combination of valves, cylinders, and pistons, all working in unison to amplify the pressure of the incoming air.
The fundamental principle at work in a compressed air booster, or pressure multiplier, is the concept of compressing the air to a pressure higher than its inlet pressure.
At the core of a booster air compressor are key components such as a pump, an inlet and outlet valve, and a cylinder, which work together to enhance the pressure efficiently.
The pneumatic operation of this system involves a piston moving within a cylinder to create pressure differentials. The incoming air, guided by the inlet valve, is forced into the cylinder, where the piston compresses it and sends it through the pipe via the outlet valve.
This results in high-pressure air being delivered by the booster. The air booster acts as a compressed air pressure amplifier, taking in low-pressure air and delivering it at a higher pressure.
Single-stage and multi-stage boosters differ primarily in their outlet pressure and the number of compression stages they employ.
A single-stage booster compresses the air only once, resulting in medium to high-pressure air.
A multi-stage booster involves several compression stages, amplifying the air pressure to a much higher level than a single-stage booster can accomplish. The choice between single-stage and multi-stage largely depends on the required outlet pressure for a specific application.
Oil-injected and oil-free boosters cater to different needs, and their usage depends on the nature of the application.
Oil-injected boosters, where the compressor and booster are lubricated with oil, are generally used in heavy-duty industrial applications. They offer a high level of efficiency and are capable of delivering high-pressure air or gas.
Conversely, oil-free boosters, which do not introduce any oil into the compressed air, are necessary in industries where air purity is paramount, such as the food and beverage or pharmaceutical industries.
A compressed air booster operates by further compressing the air intake to increase the air pressure. The process begins with the air being drawn into the first compression stage. Here, the initial pressure is amplified before being sent to the next compression stage. As the air advances through each stage, it gets progressively compressed, increasing the overall pressure.
The components include:
Compressed air boosters are instrumental in several industrial applications, including PET bottle manufacturing, pressure testing, and laser cutting.
For example, during the blow moulding process of PET bottle manufacturing, air boosters, whether vane or reciprocating piston type, play a crucial role. They address the challenge of insufficient initial pressure by elevating it beyond 150 psig (approximately 10 bar) to 580 psig (approximately 40 bar), ensuring flawless moulding and high-quality final products.
Similarly, in pressure testing and laser cutting operations, the significance of air or nitrogen boosting technology to increase pressure must be considered.
These processes necessitate high-pressure air for optimal performance and precision. However, standard air pressure is often insufficient, so boosters can help reach the requisite levels.
In laser cutting, for example, a steady, high-pressure air stream improves cutting speed and accuracy, thus enhancing productivity and product quality.
What Is A Compressed Air Pressure BoosterBooster compressors and standard air compressors differ significantly in their functionality. While both are used to increase air pressure, a standard air compressor operates independently, taking in air at atmospheric pressure and compressing it to a higher level.
On the other hand, a booster system doesn&#;t intake air from the atmosphere. Instead, it takes already compressed air from a standard compressor and boosts it to a higher pressure.
In scenarios where significantly higher pressure is required, such as in some industrial applications, a high-pressure booster is more beneficial than a standard compressor.
Why? Booster compressors are specifically designed to elevate the air pressure to significantly higher levels, making them more efficient and practical in situations that demand higher pressure outputs.
Compressed air boosters significantly contribute to energy efficiency and are a cost-effective solution in various industrial applications.
The versatility of these boosters enables them to utilise the primary feed, which is commonly used and supplied by a standard air compressor. This process reduces energy consumption and operational costs.
In high-pressure applications, these boosters demonstrate remarkable reliability. They can enhance the pressure many times greater than what is provided by the upstream source. Plus, the ability to purge the compressed air efficiently ensures optimal performance even under demanding conditions.
Several factors are critical when selecting the most suitable booster model for your specific needs.
The required pressure of the existing air system is a key factor. Different applications may necessitate varying pressure ranges, and the booster pump you select should align with these requirements.
Also, understanding the type of application &#; be it industrial or commercial &#; is equally vital. Some booster technology is better suited to specific applications, ensuring optimal performance and longevity.
For example, Control Gear supply Atlas Copco compressor boosters designed to increase the pressure of your plant air system. These boosters are capable of pressurising your pipeline air from ambient to high-pressure levels, making them an ideal choice for those in need of high-pressure compressed air.
Various boosters are available that can use the existing air system to deliver the best solution for your specific needs.
Want more information on air pressure intensifier? Feel free to contact us.
Regular maintenance of air boosters is vital for their longevity and optimal performance.
Safety is of paramount importance when operating air boosters. Always ensure operators are appropriately trained and using protective gear, such as gloves and safety glasses.
Regularly review and update safety procedures to stay aligned with industry standards.
A key safety practice includes performing a complete shutdown and depressurisation before starting maintenance work.
Also, keeping the area around the air booster clear of debris will reduce the risk of accidents.
If an unexpected issue arises, check common problem areas such as filters, valves, and seals before seeking professional assistance.
Compressed air boosters are critical components within a closed system, enhancing the pressure within to achieve high-performance results.
Given their numerous benefits, they play a significant role in various industrial processes, improving efficiency and output.
They facilitate the seamless operation of pneumatic tools, enable efficient handling and packaging, and optimise wastewater discharge treatment, among other applications.
A well-maintained air booster ensures continual productivity, reducing downtime and maintenance costs.
Also, the potential improvements an air booster can bring to your industrial processes are worth considering. The amplified pressure within the closed system can increase production speed and improve the quality of work.
For example, in manufacturing, it can help achieve precise control over machinery, resulting in finer workmanship. In energy production, high-pressure air can enhance the operation of turbines and generators.
So, implementing an air booster could be a game-changing step in your industrial process enhancement.Want to know more? Contact us for more information or to discuss your specific needs.
Compressed air is an essential requirement for several industrial processes such as sand blasting, pressure testing, and more. Ordinarily, pressurized air is supplied from standard air compressors such as rotary-screw, rotary vane, and reciprocating piston types. However, for high-powered applications, the air pressure from these systems is usually insufficient to perform a given process.
Therefore, plants may need to boost the air pressure coming from the primary feed. Special processes in industrial plants require oil-free or lubricated air at very high pressures.
High-pressure compressed air can be generated conveniently and efficiently using booster compressors. But what are they?
This article will discuss what booster compressors are, their principle of operation, and common industrial applications.
A booster system is a piece of equipment used to increase or amplify the air pressure coming from an existing compression system by passing it through additional compression stages. Booster air compressors can raise existing air pressures between 80 &#; 150 psig to as much as psig.
Using a compressed air flow booster is one of the most cost-effective ways to obtain higher process gas pressures required at industrial plants.
A booster air compressor or compressed air pressure amplifier operates on the simple principle that within a closed system (non-vacuum), the pressure increases as volume decreases. An air booster compression system comprises a receiver tank, pipework, and discharge tank.
The receiver tank has an inlet that receives compressed process air coming from a primary feed and channels it through several compression stages to further increase the pressure. Additionally, the receiver tank serves as a limited storage capacity for when the system is not actively delivering compressed air.
After going through a series of compression stages, pressurized air flows through the piping into the discharge tank which contains an outlet that supplies the gas to the site.
Air pressure boosters are utilized in several industrial applications including the following.
Automated polyethylene terephthalate (PET) manufacturing requires a continuous supply of high-pressure gas that standard compression systems cannot provide. Booster air compressors help deliver high-pressure air to blow molding machines that produce PET bottles. The blow molding technique utilizes compressed air to force the molten thermoplastic into a mold.
Pressure testing of pipelines, tubing, vessels, piping systems and more helps to determine their integrity, reliability, and leak tightness before and after being commissioned at a site. It is usually carried out during maintenance operations to ensure that essential equipment is functional and in good condition.
The compressed air or nitrogen leak test procedure (also called pneumatic testing) involves passing compressed air through the container to a required pressure range and subsequently &#;bleeding off&#; the gas via pressure relief valves located on the system under test. A pneumatic booster pump or pneumatic air pressure booster is suitable for this purpose.
Pressurized fluids such as carbon dioxide (CO2) and nitrogen gas are useful for special processes involved in hydrocarbon production. During the secondary recovery and enhanced oil recovery (EOR) phases of crude production, pressurized gas may be used to increase the pressure within the formation to stimulate the well and ramp up declining production.
Some examples are gas lift and nitrogen injection techniques. Additionally, high-pressure air or nitrogen can be used to purge hydrocarbon pipelines of impurities and toxic substances. This type of nitrogen purging for pipeline drying can help during pipeline decommissioning or commissioning.
Booster systems can amplify gas pressures of onsite nitrogen generators or air compressors to enable these processes. For short-term applications, check out NiGen&#;s selection of nitrogen generator rentals and industrial air compressor rentals.
Both air booster systems and air compressors deliver pressurized air. However, compressors that have a booster system attached can achieve up to ten times greater air pressures than standard systems. If your process requires a high range of pressures, then you will need an air pressure multiplier.
NiGen International is an industry leader in the design and fabrication of onsite nitrogen generation systems, pipeline services, and engineering services for the oil and gas industry. We provide containerized solutions to suit the most challenging operations.
For more information about our products and services or to request a quote, please contact us via our website today!
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