Why is compressed air used ?

Every day people ask this question. To the point that compressed air faces competition from
hydraulic, mechanical and electrical appliances. There are fundamental reasons why
compressed air is used over these other technologies. Let us explore the reasons why
compressed air is the 4th utility:

Safe to use
Compressed air works well even if there are extreme temperature changes. It can also be
used where there are very high temperatures such as operating a forge press or a blast
furnace. Pneumatic devices and air lines that are not tight are no risk to the safety of the
user or the serviceability of the system. A pneumatic system and its components will wear
little and therefore will have a long working life and low failure rate. Pneumatic elements are
exceedingly safe with respect to fire, explosion and electrical hazards. Pneumatics can be
used within hazardous areas without large and expensive safety apparatus. Unlike electricity
air can safely be used in damp environments and outdoors.

Versatile & transportable

Since the outlet of air escapes open there is no need for a return line, which is the case for
electrical and hydraulic systems. Compressed air can be transported over distance within air
pipelines. Typically there is an installation of a central compressed air generation system
that can supply users via a ring main with a constant pressure. The energy stored within
compressed air can widely be distributed this way.

No risk of overload.
Compressed air devices can be loaded until that stop without being damaged. This cannot
be said for an electrical system where there is a risk of danger with an overload. If the
pressure fails the work cannot be done but there is no damage to the network or its
elements.

Cleanliness
Unlike hydraulics compressed air will not cause soiling or leave puddles of oil if pipelines are
defective. This is very important in many business sectors such as food, textiles, electronics
and packaging.

Storable
Compressed air can be stored within a purpose built air receiver. The receiver is an
integrated part of a compressed air system. The air compressor will only run when the
pressure drops below a set level. Due to that fact that there is a stored capacity the work
cycle can be completed even if there was an interruption in the power network. Compressed
air can be stored within bottles for breathing. One application of this is under water diving
where there are no pipelines.

Weight
Pneumatic devices tend to be much lighter that the comparable electrical power units. This
makes a difference with pneumatic screwdrivers, nut runners and hammers.

Economical
Pneumatic components are less expensive when compared to hydraulic equivalents and
need far less maintenance.

Basic
Keep it simple stupid or KISS. The design and operation of a pneumatic system is very
simple. This makes for a much more robust and reliable system. Components are far easier
to install and can be re-used without any particular difficulty. Installation times are shorter
due to the simplicity.

Adjustable
Compressed air is easily regulated to control the movement, force, torque and speed of the
application.

Pressure Ranges

Low pressure to 10 bar (145 psig)

Most applications within industry fall within the low-pressure range of up to10 bar. In fact if
we take the simple air tool this is designed to function best at 6.2-barg (90-psig).
Compressed air systems tend to operate at unnecessary high pressures due to poor system
network design. The compressors used for this pressure range are:
• Single or two stage reciprocating compressors
• Single or two stage lubricated rotary screw compressors
• Two stage oil free rotary screw compressors
• Centrifugal oil free water cooled compressors

Medium pressure to 14 bar (200 psig)

Typical applications for this pressure would be HGV and heavy vehicle tyres. There are
specialist applications that also operate at such high pressures like deep drilling. The
compressors that would be used are:
• Two stage reciprocating compressors
• Single or two stage lubricated rotary screw compressors
• Centrifugal oil free water cooled compressors

High pressure to 40 bar (580 psig)

The compressors in this pressure range would provide air for PET bottling, diesel engine
starting, testing of pipelines and flushing tanks. They would also be used for pressure testing
transportable gas containers. The compressors used are:

• Two and three stage reciprocating compressors.

• Multi stage centrifugal oil free water-cooled compressors.

It is not unusual to combine a lower pressure compressor and a use a high-pressure

compressor as a booster. "load shaping" or "peak shaving", and is typically a smaller high
pressure compressor trickle charging a bank of huge receiver tanks. This will satisfy a large
volume demand for a short duration.

High pressure above 40 bar

Typical applications are for breathing air, either for diving or for emergency services such as
fire-fighters. The compressors used are normally reciprocating with three or more stages
Uses of compressed air

Compressed air is extremely versatile and is intensively used within all sectors of industry
today. In fact few industries do not us compressed air. Within the chapter we shall explore
some typical applications of compressed air.

Clamping or tensioning using compressed air.

This is a very common application of compressed air involving mechanisation and
automation. Pneumatic cylinders or a motor will fix the position of the tool that is necessary
for the work process. This is often performed by a linear motion or by a swivel movement.
Energy stored within the compressed air is converted into force and movement through
exertion of pressure. The amount of force is dispensed with precision set points. Once the
work is completed the pressure is exhausted and the force is released.

Pneumatic drive systems/tools

Pneumatic tools are found in all areas of industry. They perform a rotary and linear
movement. Pneumatic machinery and tools covert the energy within compressed air to a
kinetic energy for moving the piston. Vibrators, pneumatic hammers and jolting devices
belong within this category. Pneumatic power is also used by a multitude of valves and
slides, tools, adjustment devices, feed system and vehicles.

Conveying / pneumatic transportation

Mechanisation and automation often perform conveying by compressed air. Within these
applications motors and cylinders are used for times or un-timed conveyance or according to
the particular process. Air is often open blown on a conveying system to turn around product
or items that do not conform to specification. Pneumatic transportation of powders and bulk
solids through pipelines has numerous advantages when ompared to the alternative modes
available today. Many materials can be transported over one-half of a mile. The systems
have a relatively long life expectancy with low maintenance costs. Product contamination is
eliminated and fines emissions to the environment are minimal. One type of technology used
to pneumatically transport these materials is Dense Phase. It has been around for quite a
while, but was typically only used to transport just a few materials like cement and fly ash.
Over the last ten years, there have been a rapidly growing number of pneumatic conveying
installations that are using the dense phase technology to transport a very wide range of
materials from dog food to plastic pellets. Dense phase installations have grown rapidly in
the market because of the cost savings for the producers of the products and materials that
we consume. The producers of foods, plastics, pharmaceuticals, building materials, and dry
chemicals are all global suppliers. The material handling systems that are necessary to
move these products are designed to transport millions of tons annually. By reducing product
waste by only a fraction of a percent, any money spent to make improvements to these
systems will quickly be recovered.

Spraying
Spraying applications use the energy of expanding compressed air to force the material or
liquid through the spray nozzle onto the particular product. Surface treatment processes,
such as sand or gravel blasting also appear in this category. Another application of spraying
is snow making or the atomisation of liquids through a spray nozzle.

Blowing and flushing with air

Compressed air itself is the working medium with blowing and flushing. Dropping the
pressure and expanding the volume to perform the work generates the flow speed.
Examples are blowing out bottles, cleaning tools and mouldings, flushing out residue,
conveying. Compressed air in this form is also used for cooling. It is recommended that if
compressed air is used from the mains header it is regulated first. Otherwise more air will be
used at a higher pressure (see appendix, flow though an orifice). Engineered nozzles should
be recommended on open blowing applications. Save working practice states a blowgun
should be operated at no more than 2-barg.

Testing and inspection

This is where the change in pressure at the measuring point is used to determine the space,
weight and change in the shape. This allows for articles to be counted, position corrected or
the presence of work pieces to be determined.

Process control with air

This is a very common application. In fact the control of most air compressors relies on
pneumatic solenoid valves and pressure switches. In fact all pneumatic applications must be
controlled by some method. Control mechanisms actuate in different ways such as using
mechanical switches, cams or by hand. Electrical switches are also used widely. The results
determined by the pneumatic process can be used directly by the direction of the valves or
pressure switch.

Other applications

Below is a list of many applications of compressed air within industry.

• Agriculture & forestry – Plant protection and weed control, transportation of feed and
grain to and from silos, dispensing equipment, ventilation systems in greenhouses

• Chemicals industry – raw material for oxidation processes, process control and
instrumentation, remote-controlled valves, and slides within the process circuits.

• Construction trade – Drill and demolition hammers, concrete compactors, conveyor

systems for brick works.

• Crafts – staplers and nail guns, paint spraying guns, drills and screwdrivers, angle
grinders.

• Energy industry – inserting and withdrawing reactor rods, control valves and slides in
steam and coolant circuits, ventilation systems for boiler houses.

• Environmental technology – forming oil barriers in the water, enriching water with
oxygen, keeping locks free of ice, slide actuation in sewage plants, increasing pressure in
the drinking water supply.

• Food industry – Filling equipment for drinks, closing and checking devices, bulk packing
and palleting machinery, labelling machines, weighing equipment, drying and cooling.

• Health system – power for dentist drills, air for respiration systems,

• Plastics industry – transportation of granulate in pipes, cutting and welding equipment,

blowing work-pieces from production moulds, locking mechanisms for casting moulds,
shaping and adhesive stations.

• Paper-processing industry – roller adjustment and feed machinery, cutting, embossing

and pressing machinery, monitoring of paper reels, removing torn paper from rollers, air
brakes on rollers etc.

• Steel mills and foundries – carbon reduction in steel production, bundling machinery for
semi-finished products, coolants for hot tools and systems.
• Textiles industry – thread detectors, clamping and positioning equipment in sewing
machines, sewing needle and system cooling, stacking devices, blowing out residual
material and dust from sewing.

• Transport – starting aids for diesel and jet engines, air brakes for HGVs and rail vehicles,
air operated automatic doors, pressure testing gas transport containers.

• Wood processing industry – roller adjustment from frame saws, drill feed systems,
frame, glue and veneer presses, removal of chips and sawdust from work areas, automatic
pallet nailing.