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Kaishan USA | November 22, 2023 | Uncategorized
Industrial air compressors are used in many applications in the aviation industry, including airplane and jet ground support, repair and maintenance.
Like automobile manufacturing, the sprawling aviation industry has a wide range of applications using compressed air.
Industrial air compressors can be found in almost every aspect of the industry, including the following:
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- In planes themselves, air compressors maintain cabin pressure levels, supply air to the cockpit and help operate environmental controls.
- In aircraft manufacturing, compressed air is used throughout the airframe assembly process as engines, wings and the fuselage are moved into place. It drives pneumatic tools like grinders, hammers and welding equipment and provides pressurized air for sandblasting and finishing.
- In testing, industrial air compressors power the simulators that subject engines to conditions they might encounter in flight. In addition, avionics bench testing equipment often relies on compressed air.
- In aircraft hangars coast to coast, compressors are involved in airplane and jet ground support, repair and maintenance. They power many of the same tools used in aircraft manufacturing. And they help transfer fuel from one location to another.
Even the major aircraft manufacturers like Boeing and Lockheed Martin use compressed air for tasks like operating pneumatic tools, painting and structural testing.
The aviation industry needs high-quality compressed air not only for sensitive electronics and engine manufacturing, but also to prep and paint a plane’s exterior.
Types of Compressors
There are many different kinds of compressors, but facilities use one of three main types for the most part: reciprocating, centrifugal or rotary screw compressors. Each offers some unique benefits, depending on the application:
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- Reciprocating compressors. A reciprocating piston compressor acts like an automobile engine, drawing air into a compression chamber as it moves in one direction, then compresses it when it reverses and moves in the opposite direction. A recip is inefficient and has a limited duty cycle, so it is not for every application. Many customers find they are very noisy as well.
- Centrifugal air compressors. Centrifugal compressors, also called dynamic compressors, create compressed air by increasing the air’s velocity using an impeller then slowing it with a diffuser. Extremely efficient, especially at high volumes, centrifugal compressors can produce a lot of air from a small footprint and are very durable. Unfortunately, they are usually large (thousands of HPs) and have a limited pressure range; they are sold in multi-stage designs to get to pressures above 100 PSIG.
- Rotary screw compressors. Rotary screw compressors have two rotors that rotate through a compression chamber and pressurize the air until it reaches the desired pressure. They range in size up to 700 HP. Because they have fewer moving parts, rotary screw compressors are more reliable than other types of compressors. They can handle a 100% duty cycle—we recommend setting up your compressed air system so that they operate as close to full load as possible. In addition, they are very energy efficient and good at variations in demand. Best of all, they deliver high-quality air, meeting the needs of a wide variety of aviation applications, especially for electronics and painting.
Generally, a centrifugal air compressor is most cost-effective for high-volume applications (above 2,500 CFM). A reciprocating compressor is the best choice for low-volume applications (less than 20 CFM). But screw compressors are the best for everything in between. For more on the subject, read our blog post, “Which Type of Air Compressor Is Best for Your Application?”
Cavernous facilities often mean large manufacturers will do better with multiple rotary screw compressors than with a single centralized industrial air compressor.
Rotary Screw Air Compressors—the Best Choice
Because of their reliability, efficiency and long life, rotary screw air compressors are the industrial air compressors of choice for most applications. Even original equipment manufacturers or major fleet operations with thousands of employees usually select rotary screw machines because their jumbo-jet-sized facilities are too large to make centralized units practical. In addition, rotary screw air compressors are known for producing steady streams of high-quality compressed air and handling large-capacity loads. And they are backed by the industry’s best warranties—Kaishan’s KRSP and KRSP2 screw compressors are backed by a lifetime warranty on the airend.
Kaishan’s KRSP and KRSP2 screw compressors are backed by an unmatched lifetime airend warranty.
Quality Is Paramount
Since aviation is one of the most regulated industries, facilities at all levels are subject to standards designed to ensure the safety not only of passengers, but people on the ground as well. Strict quality control standards monitor every aspect of aircraft manufacturing and operation. And compressed air is no exception.
Today’s advanced aircraft are controlled by sophisticated electronics that must be manufactured and serviced with high-quality compressed air.
Manufacturers and maintenance facilities regularly monitor dew points, oil carry-over and other contaminants, identifying the flaws in components or parts that might endanger the flying public. The quality control measures extend to parts manufacturers, with all electronics and engine components under careful supervision.
As a result of the aviation industry’s regulatory environment, many companies choose to use oil-free compressors like the new Kaishan KROF oil-free rotary screw air compressor.
Kaishan KROF: Changing the Rules of the Oil-Free Game
Kaishan’s new oil-free compressor, the KROF, sets new standards for reliability, efficiency and warranty protection, producing ISO 8573-1, Class 0 oil-free compressed air. It is available in 100-, 125- and 150-psig models with integrated air or water cooling.
The KROF has a host of robust features that make it the best choice for demanding oil-free applications:
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- Oversized stainless-steel precoolers on each stage that lower temperatures for both intercoolers and aftercoolers.
- Integrated lubrication passages between stages to ensure proper lubrication and reduce leak points, service requirements and lifetime costs.
- Angular contact and roller bearings that eliminate the need for an outdated balance piston and require no maintenance to achieve proper thrust loading.
- Hydraulic inlet valves to increase reliability in contaminated environments, with closed-system hydraulics ensuring positive sealing and controlling valve actuation through all operating pressures.
- Oversized moisture separators equipped with reliable, zero-loss drains that keep moisture from passing between stages. The drains have diaphragm valves that allow them to handle contamination better than traditional, orifice-style drains.
- A dual-centrifugal fan to reduce noise.
Industry-Leading Warranty
Because of that built-in Kaishan reliability and longevity, the KROF is backed by an industry-leading five-year warranty on major components, including the airend.
Best of all, it is the only oil-free compressor designed and engineered in the U.S. for a global market. And it is manufactured at our state-of-the-art, 65,000-square-foot plant in Loxley, AL.
As with any oil-free compressor, the KROF needs inline compressed air filters, sized properly for your application, to remove water vapor, dirt and other contaminants from the atmospheric air it takes in. In addition, the total cost of ownership of any oil-free unit is higher than the TCO of an oil-lubricated air compressor because of the greater initial cost, increased maintenance requirements and higher energy consumption required for oil-free operation.
Local Help
Industrial air compressors offer an important fourth utility throughout the aviation industry, and selecting the right compressor for your application is critical. Kaishan can help. We work with a nationwide network of independent distributors, who can provide on-site help and consultation. They are skilled in using the advanced technology needed to optimize the operation of your industrial air compressor.
Key Takeaways
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- Compressors can be found in a wide range of aircraft applications, including airplane and jet ground support, repair and maintenance.
- Rotary screw air compressors are the aviation sector’s industrial air compressors of choice because of their reliability, efficiency and long life.
- Since aviation is one of the most regulated industries, facilities at all levels are subject to strict quality standards.
- As a result of the aviation industry’s regulatory environment, many companies choose to use oil-free compressors.
Let Us Help
Selecting the right industrial air compressor is critical to the operation of your compressed air system and all the processes that rely on that system. If you need help making the right choice, get in touch with the experts at Kaishan. Contact us today.
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Like automobile manufacturing, the sprawling aviation industry has a wide range of applications using compressed air.