Compressed air is widely used in the industrial sector, manufacturing, healthcare, and numerous other fields. Indeed, approximately 10% of commercial energy is used to produce it.
Air compressors can compress air up to certain realistic limits. 13 bar is a common pressure limitation for compressors without pushing the system too far. When requiring higher pressure levels, adding an air booster to the compressor system amplifies existing pressures to higher levels.
Using both a compressor and an air booster is more efficient, less costly, and safer. When requiring 40 bar for PET bottle blowing or 300 bar in higher-pressure environments, a booster significantly extends the capabilities with no need to upgrade your existing air compressor.
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What is a Compressed Air Booster?
It is best thought of as a force multiplier to existing air pressure levels. A booster further pressurises air that a reliable air compressor has already compressed.
Some boosters work by a ratio from the existing pressure level to the maximum output level. These might be expressed in the literature as a 5:1 booster, meaning it boosts 5 times the existing pressure level. This is up to the maximum capabilities of the booster itself. For example, a 5:1 booster potentially boosts 13 bar pressure to 65 bar or higher.
The maximum pressure level of high-end air boosters is 100 bar. However, this varies by model. Highly configured, advanced systems are capable of hundreds of bar of pressure output when planned properly. J LL Leach works with its customers to build appropriate systems to match their unique needs.
Boosters use pre-compressed air from a compressor. To increase pressure levels, air is moved through a series of pistons, valves, and cylinders. The highly compressed air is then released via the outlet valve to where it is required.
Types of Compressed Air Boosters
There are different types of air boosters on the market, including single-stage, two-stage, and variable-speed versions.
In some circumstances, there are oil-free air pressure boosters and oil-injection versions; the latter is more common. Oil-free boosters are appropriate for food and beverage industries, healthcare, etc.
Below are the three types of compressed air boosters:
Single-Stage Boosters
A single-stage air booster receives compressed air through an inlet valve and then compresses it further in a single process.
Compressed air between 2 and 10 bar is passed through the single stage to reach between 15 and 30 bar (some single-stage boosters can achieve 40 bar).
Two-Stage Boosters
Two-stage boosters compress pressurised air once and then do it a second time to further increase its final pressurisation level. Therefore, the first stage may achieve 30 bar pressurisation of the air, whilst the second stage further increases this to 40 bar.
A 40 bar pressure is required for PET bottle blowing and other applications where lower pressurisation would be insufficient.
Variable-Speed Boosters
An advanced option is the variable-speed air booster. These are heavily configurable, adjusting pressurisation settings to deliver real-time air on demand.
Flexible air production levels and compression settings to match exact production needs increase energy efficiency. This avoids over pressurised air which is highly energy-consumptive and needlessly adds additional wear and tear to equipment.
Key Components of a Compressed Air Booster
The common key components of a compressed air booster are:
The inlet valve permits air to enter the main compressor. Filtration is also required to clear the ambient air before it is compressed. At the other end, an outlet valve is the release point for the pressurised air, usually coupled with a pressure gauge.
The compression chamber is where the magic happens. Air is compressed using pistons or other methods before it is released.
Built-in sensors, gauges, and control systems allow for the management and configuration of the booster, as well as pressurisation levels and flow rates.
Benefits of Using Compressed Air Boosters
A plant or other operation often has a myriad of compressed air requirements. If so, they usually require a selection of air pressure levels to function. This is inconvenient enough, but when some applications require 30 bar, 40 bar, or even higher air pressure, a standard air compressor will not suffice.
Instead, it is better to use one or more air boosters. For example, when there are two main types of equipment requiring different pressure levels, multiple boosters allow for continual usage at the appropriate air pressure. It is no longer necessary to supply the correct air pressure to one outlet and overspecified air to the other. This saves money by reducing waste through overpressurisation.
It is never a good idea to push new or older compressors to the maximum. This increases the likelihood of wear and tear or, worse still, equipment damage. With an air compressor and boosters, the compressor is dialled back to deliver lower pressure levels, protecting the capital investment rather than putting it at risk.
Installation and Maintenance Tips
An air booster is ideally placed within an air compressor system after the compressor but before the cooling system. This permits the increase in air compression and the heated air to be cooled down significantly before reaching the outlet valve. This approach also avoids potential pressure losses. Monitoring air release at the right air pressure via a pressure gauge is best.
No matter how new your air booster is, scheduled maintenance is required. This includes replacing worn seals, valves, and filters. Wear, dirt, and clogging all impact these respective parts. Early replacement avoids unnecessary operational failures.
Discuss with J LL Leach how they can help with a planned maintenance package for your air compressor system.
Common Applications of Compressed Air Boosters
Compressed air boosters are required in various industries, applications, and situations. Low air pressure is often insufficient for the planned activities.
Here are a few of those types of situations:
Manufacturing: packaging, PET blowing, laser engraving, and many other applications within the manufacturing sector are relevant. These require 20 or 40 bar, which is beyond the specification of a standard air compressor.
Automotive: parts assembly and painting/respraying depend on pressurised air for pneumatic air tools and paint spray guns. Continuous high pressure is required, or the air tools will not function.
Power plants/energy sector: plants experience situations where necessary pressure levels exceed 50 or 100 bar. High-end air boosters solve this.
Choosing the Right Compressed Air Booster for Your Needs
When choosing an air compressor system, it is essential to consider both the expected pressure levels and the typical flow rate. This assessment quickly confirms whether one or more compressed air boosters are necessary within the system.
Even often overlooked aspects, such as the ambient temperature inside the plant or peak humidity levels, require consideration.
Failure to use a properly configured air system leads to unanticipated issues, such as an inability to deliver high enough pressure or at a sustained flow rate to satisfy all operational needs.
Talking with air compressor experts is necessary to obtain a properly configured system that is fit for purpose.
Conclusion
Air boosters are vital for numerous air compressor systems. Without one, higher air pressure levels are unobtainable or extremely limited. Boosters deliver targeted pressure levels, reduce overall energy consumption, and improve the longevity of your equipment.
Discuss your compressed air requirements with our team at J LL Leach. We can determine whether boosters are required in your air system.
