Air Compressors in the Chemical Industry

J Ll Leach is supporting the chemical industry with reliable Atlas Copco air compressors, supplied and installed from our Stoke, Birmingham and Shrewsbury branches.

In the chemical manufacturing process, compressed air is the fourth utility, a mission critical asset just as important as electricity, water, and gas.

It’s used for everything from product drying and instrumentation to nitrogen generation and emergency shutdown systems. Because air compressors play such a vital role, a system failure can halt production, destroy entire batches, and result in compliance violations – often all at the same time.

In this guide, we cover what’s at stake when it comes to air management for the chemical industry. It will help you understand what it takes to guarantee absolute purity, meet complex legal responsibilities, and enhance profitability by optimising your system performance with an expert partner such as J Ll Leach.

The High Cost of Contamination: Why ISO Class 0 Air is Non-Negotiable

Wherever compressed air is used and compressed air comes in direct contact with the product, purity is crucial.

Solid particles, water, and oil aerosols can cause chemical reactions and contamination that can spoil a batch, trigger product recalls, and incur significant regulatory fines. ISO 8573-1 is the industry standard specification for the quality of compressed air.

ISO 8573-1 Class 1 is typically required for most applications; however, for the most sensitive chemical production processes and pharmaceutical applications, ISO 8573-1 Class 0 is necessary.

ISO 8573-1 Class 1 specifies an oil content of ≤ 0.01 mg/m³. Oil-lubricated compressors typically meet this with high-efficiency filtration.
ISO 8573-1 Class 0 is the most stringent classification, requiring that oil contamination can’t enter the process.
A point to note, however, is that filter-based solutions are not necessarily Class 0. In fact, a risk of filter failure/bypass and catastrophic contamination is always present with these systems. True Class 0 high quality compressed air can only be assured by the use of certified 100% oil-free air compressors, such as the Atlas Copco ZR/ZT range, which are designed with zero oil in the compression chamber.

Atlas Copco Air Compressors: Technical Overview

To meet the diverse demands of chemical applications, we offer a comprehensive range of compressors tailored to specific needs:

ZR/ZT Oil-Free Rotary Screw: These Class 0 certified machines are ideal for critical applications requiring 100% oil-free compressed air. They are often used in the chemical industry for process air and instrumentation.
ZH Centrifugal Compressors: For large scale chemical plants needing high flow rates (up to 40,000 l/s), these turbo compressors offer vibration-free performance.
AQ Water Injected Screw Compressors: Offering another route to oil-free air, these units use water lubrication for high pressure efficiency and are suitable for specific niche applications.

Matching Air Quality to Core Chemical Applications

Matching aeration requirements to different chemical processes in your chemical plant will often result in a range of air purity requirements.

Designing a system that truly meets your needs involves selecting industrial air compressors for the chemical sector and air treatment that are tailored to the specific application. This approach ensures that air is not over-treated for processes that do not require it, while delivering absolute purity where it is needed most.

Application	ISO 8573-1 Class Required	Recommended Technology	Required Air Treatment
Process Air (Product Contact)	[1:2:0]	Oil-Free Screw or Centrifugal	Desiccant Dryer, Carbon Filtration
Instrument Air	[2:2:1]	Oil-Free Screw	-40°C PDP Desiccant Dryer, Coalescing Filters
Nitrogen Generation	[1:1:0]	Oil-Free Screw	-70°C PDP Desiccant Dryer, Carbon Tower
Pneumatic Conveying	[1:3:0]	Oil-Free Rotary Screw	Aftercooler, Water Separator
Air Curtains	[1:4:1]	Oil-Free or Injected	Refrigerant Dryer

Beyond standard aeration, compressed air is crucial for powering pneumatic conveying systems used to convey powders and granules safely. Furthermore, fluid pumping systems are used to move aggressive liquids, while air tools are essential for plant maintenance. Even in oil and gas storage terminals, reliable air is required to operate actuation valves.

A System Built for Safety and Compliance

Operating a pressurised system in a potentially hazardous environment is governed by strict UK legislation and industry regulations. Failure to comply can result in prosecution, invalid insurance, and significant risk to personnel.

Navigating Your Legal Duties: PSSR and ATEX

Two key regulations are central to chemical plant safety:

Pressure Systems Safety Regulations 2000 (PSSR)

To reduce the risk of causing serious injury through the uncontrolled release of stored energy. Compliance is achieved through a legal document called the Written Scheme of Examination (WSE), which identifies every pressurised component, the type of inspection required, and safe operating limits.

At J Ll Leach, our ‘Competent Person’ can certify your WSE, ensuring you maintain compliance with industry regulations for legal operation. For more information, see our Guide to Compressed Air Compliance in the UK.

The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) and the ATEX Directives

In areas where flammable gases, mists, or combustible dusts create a potentially explosive atmosphere, all air equipment must be certified to prevent ignition. ATEX certified air compressors are specifically designed for safe operation in these hazardous zones and are a legal requirement under DSEAR. Meeting these safety standards is non-negotiable for petrochemical applications.

Designing a Resilient Infrastructure

A compliant system goes beyond the compressor itself. The entire infrastructure must be designed for purity and reliability. Corrosion-resistant stainless steel pipework is often required to protect the purity of compressed air from contaminants introduced by the distribution network.

For mission-critical processes, redundancy, such as a duty/standby compressor arrangement, is crucial to maintain continuous air uptime during both planned maintenance and unexpected failures.

The design and installation of such systems require specialist expertise, provided by a Dedicated Projects Team for the chemical and petrochemical industries.

A complete system also relies on a correctly specified air treatment chain, including high performance compressed air filtration stages where air is filtered via activated carbon, High-Tech Compressed Air Dryers to prevent moisture related reactions, effective Air Compressor Condensate Management to handle hazardous waste, and onsite Atlas Copco Nitrogen Generators for reliable inerting.

From Energy Waste to Profitability

Energy can account for up to 80% of a compressor’s total cost of ownership, making energy efficiency in compressed air systems a significant lever for profitability. Start with a compressed air audit. Compressed Air Leak Detection & Audit Services, data logging, and airflow monitoring will uncover hidden energy waste and save thousands.

Key optimisation technologies include:

Variable Speed Drive (VSD) Compressors: VSD compressors vary motor speed to meet real-time demand, typically saving 35-50% of energy in facilities with variable loads.
Heat Recovery Systems: As much as 94% of the electrical energy used by a compressor is converted to heat. A heat recovery system captures this waste energy to produce hot water or space heating and typically pays for itself in 3 years or less.
Intelligent Monitoring: Remote monitoring platforms such as Atlas Copco’s SMARTLINK provide complete transparency into system health and performance.
SMARTLINK Benefits:
- Remote alerts for air leaks or pressure drops
- Predictive maintenance via vibration & pressure trends
- Real-time energy use tracking
- Cloud dashboard accessible 24/7

The J Ll Leach Advantage: Your Local Compliance Partner

For over 80 years, J Ll Leach has provided specialist air solutions for the chemical and UK industrial sectors. We have extensive experience in the chemical sector and its associated challenges, and we understand your needs through our work with local industry leaders, including Esterchem, Eternis, and Minchem.

Operating from Stoke on Trent, we service chemical plants throughout Staffordshire, West Midlands, Merseyside, Greater Manchester, and Cheshire. We are local to your operation, so you benefit from 24/7 onsite engineers and regional spare parts, enabling quicker turnarounds and less downtime.

We position ourselves as your compliance focused partner, delivering “Compliance as a Service” packages that bundle expert support for ISO 8573-1 testing, PSSR management, and ATEX system specification. We help you manage the legal burden, allowing you to focus on chemical products and production.

Book your audit today. Let our engineers identify savings, reduce risks, and bring your system into full compliance. Fast.

Frequently Asked Questions

What is the best air compressor for chemical manufacturing?

For most chemical production processes, oil-free rotary screw compressors (like the Atlas Copco ZR/ZT series) are the best choice. They ensure that compressed air must be absolutely pure (Class 0), preventing product contamination.

Are Atlas Copco compressors suitable for ATEX zones?

Yes, specific models within our range of compressors are ATEX-certified, ensuring they are safe to be powered by compressed air in environments with explosive gases or dusts.

How can I ensure my compressed air is contamination-free?

Using a Class 0 oil-free compressor is the first step. Additionally, air is filtered via coalescing and carbon filters, and treated with desiccant dryers to remove moisture, ensuring high-quality compressed air.

What are the maintenance requirements for chemical plant compressors?

Chemical air compressors require rigorous maintenance, including regular oil sampling (for injected models), vibration analysis, and checking safety systems. Our SMARTLINK technology helps monitor these needs remotely.

How does VSD technology help in energy savings?

Variable Speed Drive (VSD) compressors adjust the motor speed to match the air supply demand. Since compressed air could account for significant energy costs, VSDs can reduce energy consumption by up to 50%.