Do I Need an Air Compressor Water Separator?

In the process of pressurizing ambient air, your air compressor generates air that is hot and moist. When this compressed air cools, it becomes liquid water that can enter the distribution system and cause system-wide corrosion that damages pipes and air system components, compromises the performance of downstream equipment, reduces system efficiency and degrades the quality of manufactured goods. Removing high concentrations of liquid from the compressed air system via an air compressor water separator is critical to ensuring the reliability and efficiency of the compressed air system and pneumatic equipment, as well as the quality of finished products.

What is an Air Compressor Water Separator?

While air dryers remove water vapor from the air and air compressor filters capture oil aerosols, dirt and other contaminants, both of these components struggle to remove high concentrations of liquid. This is where air compressor water separators shine as they are specifically designed to remove bulk liquid water before it can travel through the air treatment equipment, preventing damage to air system components, tools, machines and finished products. 

Air compressor water separators excel at removing high concentrations of water due to the method of operation. Hot, wet, compressed air enters the aftercooler causing it to cool, condensing some of the moisture into liquid, then travels to the water separator and is forced through a chamber into a tubular or conical vortex where centrifugal forces spin the water out of the compressed air. The spun water droplets fall into a collection area, which must be drained, and the compressed air exits from the top of the separator.  With the majority of bulk liquid removed, the still wet compressed air can then safely proceed to the filters and dryer, providing clean and dry compressed air to the distribution system.

The High Cost of Ignoring Water in Your Compressed Air System

But do you really need an air compressor water separator? And what happens if you don’t drain water from an air compressor? Many compressed air systems will benefit from the addition of a water separator, especially those that experience high concentrations of liquid water. For that reason, most rotary screw compressors come standard with aftercoolers and water separators. This is because if water is not removed from the compressed air system, there are several costly consequences, including:

●  Equipment damage: Unchecked water in the system will result in rust and corrosion within the air system components and delivery system, which can be transmitted to the pneumatic equipment that relies on compressed air to operate. Both air system components and the tools and equipment it powers may experience poor performance or failure due to corrosion.

●  Operational inefficiencies: In addition to causing equipment damage and failure, corrosion can enter the air delivery system, accumulate and cause blockages. Blockages in air delivery lines will result in pressure drops that negatively impact the performance of the tools and equipment and will force the air compressor to work harder to meet air demand, increasing electricity consumption and causing wear and tear and premature failure of the air compressor.

●  Product contamination: When compressed air that contains excess moisture is applied in the production of products, especially in sensitive applications such as food and beverage and pharmaceuticals, it can result in contaminated products, waste and recalls. In addition, if wet compressed air is used in the application of paints and coatings, it will result in a poor-quality finish, waste and re-work.

What is the Best Location for a Water Separator?

The ideal location for a water separator is between the air compressor’s aftercooler and wet air receiver tank. This optimal arrangement enables the water separator to remove most bulk liquids, reducing the workload and strain on air treatment system components downstream.

A Water Separator is Your First Line of Defense

As mentioned earlier, a water separator is key to removing high concentrations of liquid water from your system; however, it is just one part of a larger system of air treatment components that work together to ensure clean, dry air. Other essential components include:

• Air dryers: Air dryers excel at removing the remaining water vapor and help to achieve the proper pressure dew point of the system.
• Compressed air filters: Compressed air filters remove very fine aerosols, oil, as well as particulates and odors.
• Drains:  Water separators, refrigerated dryers, and filters are unable to remove liquids from the compressed air system without proper draining.
• Service and repair: Proper installation and maintenance, is essential for efficient, effective and reliable performance of the air compression system.

Frequently Asked Questions

Q: How do you separate water from compressed air?

A: The most effective method for removing water from your compressed air system is a multi-stage approach in which a aftercooler with water separator removes bulk liquid water, an air dryer removes water vapor and filters remove remaining contaminants. Our team can help you design the right system for your needs.

Q: What happens if you don’t drain your water separator?

A: An undrained water separator becomes ineffective. Collected water will eventually be picked up in the airflow and carried downstream, leading to the same corrosion and contamination issues you were trying to prevent. Regular draining, either manually or with an automatic drain, is key to top performance.

Q: Does every industrial air compressor need a water separator?

A: Nearly every industrial compressed air system will benefit from the inclusion of a water separator. It is the most cost-effective way to remove large volumes of water and protect more expensive downstream equipment, such as air dryers, filters and pneumatic equipment.

Partner with JHFOSTER for a Complete Air Treatment Solution

JHFOSTER is more than a distributor. We are a partner in your success. We don’t just sell parts, we evaluate, design, integrate and support complete systems tailored to your application. Partnering with JHFOSTER will help you move from inefficient to streamlined operations. Contact us today for an expert evaluation of your compressed air system. Our technicians can help you identify the most effective solution to protect your equipment, enhance performance and quality and improve your bottom line.