kaishan logoEngineering the futurekaishan logoEngineering the futurekaishan logoEngineering the futurekaishan logoEngineering the future
  • Industries
      • Aerospace
      • Agriculture
      • Amusement Parks
      • Aquaculture
      • Automotive
      • Aviation
      • Biogas Production
      • Brewing
      • Building Materials
      • Carbon Capture and Storage
      • Cement
      • Chemical
      • CNG
      • Construction
      • Defense
      • Dry Cleaning
      • Electric Car Battery Production
      • Electronics
      • Fertilizer
      • Food and Beverage
      • General Manufacturing
      • Glass
      • Healthcare
      • Industrial Gasses
      • Laser Cutting
      • Life Sciences
      • LNG
      • Metallurgy
      • Mining
      • Oil and Gas
      • Painting
      • Power Distribution
      • Power Generation
      • Pulp and Paper
      • Railway
      • Semiconductor
      • Textile
      • Transportation
      • Wastewater Treatment
      • Winemaking
      • Woodworking
  • Products
      • Rotary Screw Air Compressors
      • Orc Power Generators
      • Industrial Vacuum Pumps
      • Steam Screw Expanders
      • Centrifugal Air Compressors
      • Rotary Screw Gas Compressors
  • Parts and Service
  • Resources
    • Blog
    • Calculators
    • Case Studies
    • Data Sheets
    • Videos
    • Warranty
    • Webinars
    • Whitepapers
  • About Us
    • Careers
    • News
    • Supporting Veterans
    • Why Kaishan?
  • Contact Us
  • Industries
    • –
      • Aerospace
      • Agriculture
      • Amusement Parks
      • Aquaculture
      • Automotive
      • Aviation
      • Biogas Production
      • Brewing
      • Building Materials
      • Carbon Capture and Storage
      • Cement
    • –
      • Chemical
      • CNG
      • Construction
      • Defense
      • Dry Cleaning
      • Electric Car Battery Production
      • Electronics
      • Fertilizer
      • Food and Beverage
      • General Manufacturing
      • Glass
    • –
      • Healthcare
      • Industrial Gasses
      • Laser Cutting
      • Life Sciences
      • LNG
      • Metallurgy
      • Mining
      • Oil and Gas
      • Painting
      • Power Distribution
      • Power Generation
    • –
      • Pulp and Paper
      • Railway
      • Semiconductor
      • Textile
      • Transportation
      • Wastewater Treatment
      • Winemaking
      • Woodworking
  • Products
    • –
      • Rotary Screw Air Compressors
      • Orc Power Generators
    • –
      • Industrial Vacuum Pumps
      • Steam Screw Expanders
    • –
      • Centrifugal Air Compressors
      • Rotary Screw Gas Compressors
  • Parts and Service
  • Resources
    • Blog
    • Calculators
    • Case Studies
    • Data Sheets
    • Videos
    • Warranty
    • Webinars
    • Whitepapers
  • About Us
    • Careers
    • News
    • Supporting Veterans
    • Why Kaishan?
  • Contact Us
  • Industries
  • Products
  • Parts and Service
  • Resources
  • About Us
  • Contact Us
✕
construction
Signs Your Air Compressor Needs Repair or Replacement
October 30, 2024
High CFM, low PSIG
CFM vs. PSI: What You Need to Know to Size an Air Compressor
November 13, 2024

The Impact of Temperature on Air Compressor Efficiency

CONTACT US







Kaishan USA | November 6, 2024| Uncategorized

Outdoor temperatures of 100°F air (or higher) make your air compressor struggle. And that spells trouble for air compressor performance.

Outdoor temperatures of 100°F air (or higher) make your air compressor struggle. And that spells trouble for air compressor performance.

Elevated outdoor temperatures can have a significant, negative impact on air compressor efficiency. 

If it’s already hot outside, that heat will have to be removed, or your compressed air system efficiency will suffer. You can’t cool things off with hot air. 

And while it may not be hot outside right now, heat is an issue you will want to keep in mind as you are doing updates on your system (usually in winter months). And as you’ll see below, not all heat problems come from the outside.

The Heat Comes On

There are two ways heat enters your compressed air system.

First, the temperature of the outside air you draw into your compressor brings outdoor temperature inside. If it’s 100°F outside, all that heat comes right into your unit. And you’re starting out behind the eight ball.

Second, during the compression process, your compressor generates heat as a part of normal operations. It’s called the heat of compression, and it occurs naturally as the air molecules are jammed closer together. The higher the ratio between the discharge and suction pressure, the more heat you generate. Plus, the faster your compressor operates, the more heat it produces.

The ambient air that enters your system, presumably at 70°F, will reach 175°F-200°F in an oil-lubricated screw compressor, according to Air Compressor Guide. You’ll need cooling and drying equipment to condition that air down to a more manageable level. However, it will still be 10°-20°F higher than your incoming air. We call this difference the approach temperature.

As a result, if your intake air is at 110°F, you will struggle to get the compressed air you send downstream below 120°-130°F.

And that will kill a lot of equipment throughout your compressed air system. Those high compressed air temperatures will:

  • Shorten the life of the oil and the compressor itself. For every 10°F you operate the compressor above its normal operating temperature, the oil life is cut in half.
  • Increase all your costs, including electricity bills and maintenance expenses. 
  • Produce poor air quality, including pass-through of oil and water. 
  • Damage end-use tools and equipment, degrading lubricants and seal materials. 
  • Cause corrosion and scale buildup and may even result in freezing in colder climates, as the water vapor in hot air is released.

That negative impact will produce ripple effects throughout your system.

Ripple Effects Downstream

Excess heat will make a dryer work much harder. And if the dryer’s not working, filtration will not work properly either.

So, you will be sending water and other contaminants into your end-use equipment. That’s going to cause problems with applications, like painting, that require high-quality compressed air. And it will ultimately damage some end-use tools.

In the case of applications where there is direct contact with products, those products could be contaminated.

Compressed air painting

High temperatures are one likely cause of the top complaints we get from painting operations concerning moisture and impurities in their compressed air supply. 

One of the top complaints we receive from paint shops, for instance, is the water, oil and other particles in the air flow that causes fisheyes and other imperfections in the otherwise flawless surface the shop’s customers expect. (There are other causes of contamination, of course, such as undersized filtration and drying equipment, lack of maintenance and poor environments.)

However, realistically, most air filtration and treatment systems are not designed to take a lot of heat. So, once again, if the incoming air is in the triple digits, keeping temperatures under control will be a challenge.

How Most Compressors Deal with Heat

Air compressors used in most industrial applications are oil-flooded, helping them dissipate that heat.

Oil-flooded rotary screw air compressors use a fine mist of oil to keep the compressor’s airend from overheating. The cool oil is injected into the compressor to keep the discharge temperature down. (To see a video showing how our oil-flooded unit uses oil for cooling, visit our KRSP2 page.

As a result, we consider oil to be the lifeblood of your compressor, removing heat and impurities from the compressed air flow. We recommend changing your compressed air system’s oil separator and lubricant every year (or 8,000 hours of operation) or as per machine guidelines. And we recommend that you sample oil every 2,000 hours or 1,000 hours for food-grade lubricant. (For more on oil selection, maintenance and sampling, read our blog post, “Choosing the Right Rotary Compressor Oil”).

However, not all applications can use oil-flooded air compressors.

The Special Heating Challenge for Oil-Free Compressors

There are many applications like food and beverage, healthcare, medical, electronics  and semiconductor where even that small amount of oil would contaminate or ruin end products. As a result, these industries require oil-free air compressors.

Oil-free units do not use oil as a cooling agent (although gear oil floods the jackets in the airend to help cool the discharge air and keep the housing temperatures lower).

041-02

That makes airend cooling even more of a challenge for oil-free units. The ambient air that enters your system will reach 350°F in an oil-free rotary screw air compressor. As a result, Kaishan goes the extra mile, equipping its KROF two-stage oil-free rotary screw air compressor
with oversized coolers and high-temperature, stainless-steel pre-coolers.

Removing the Heat

There are several ways to get rid of that heat, including ventilation, forced air and water cooling.

Ventilation

Ventilation is one of the most critical considerations for the operation and longevity of your compressed air equipment. The goal is to remove all that heat generated during compression and keep it from recirculating back into the room.

There are several different ways to ensure your compressor is ventilated, including louvered vents and forced ventilation. For more information on best practices for ventilation, see our blog post, “Air Compressor Cooling.”

krsd125

All Kaishan rotary screw air compressors have forced air cooling, including our KRSD direct-drive rotary screw air compressors, which employ an axial fan.

Forced Air Cooling

Compressors larger than 25 HP usually require forced ventilation. An axial or centrifugal fan draws in ambient air and passes it over a heat exchanger to extract the heat, thus cooling the compressor.

All Kaishan rotary screw air compressors have forced air cooling. Our KRSB belt-drive and KRSD direct-drive rotary screw air compressors employ an axial fan, while our KRSP and KRSP2 premium rotary screw air compressors use a centrifugal fan.

Water Cooling

Water can also be substituted as a cooling medium instead of air. In a water-cooled compressor, a pump moves water through tubing around the compressor body, extracting the heat. The water then goes to a radiator, usually a shell and tube heat exchanger, to cool. Water cooling is more common in larger units (more than 300 HP).

Maintenance

No matter which cooling methods you use, you’ll need to adopt good maintenance practices to keep your system functioning properly. We encourage all our customers to develop several different levels of maintenance:

  • Regular cleaning and inspection of filters and drain traps, removing any obstructions or replacing clogged filters.
  • Oil sampling, ensuring your oil has the remaining life to keep the compressor properly lubricated, thus reducing operating temperature.
  • Preventive maintenance, doing routine procedures like oil changes and filter replacements on a regular schedule. 
  • Predictive maintenance, closely monitoring data from sensors located throughout your compressed air system and taking action to deal with problems before they become serious.

Good maintenance, after all, is preferable to unplanned shutdowns, which can result in lost production time and ruined processes and materials. You may have to schedule a planned shutdown to address the issues in a comprehensive way. And while no one likes a planned shutdown, it’s much better than the unplanned kind.

For more information on preventive and predictive maintenance, see our blog post, “The Differences Between Air Compressor Preventive Maintenance and Predictive Maintenance. And Why You Should Care.”.

Beating the Heat Is a Team Effort

The larger (and more critical) your compressed air system, the more you will benefit from having a compressed air consultant’s advice and assistance. From sizing ductwork to helping you set up good maintenance practices, a professional’s advice can help you deal with heat problems that could otherwise damage your equipment or even cause unplanned downtime.

Air compressor performance

Your local professional can help you control temperatures inside your air compressor, boosting air compressor performance and compressed air system efficiency.

We work with a nationwide network of independent distributors, who can provide expert advice and support in setting up and operating your system to deal with high temperatures. In the long term, they can help you maintain and optimize your system, enhancing air compressor performance and compressed air system efficiency.

Key Takeaways

  • Elevated outdoor temperatures can have a significant, negative impact on air compressor efficiency.
  • The outside air you draw into your compressor brings outdoor temperature inside. If it’s 100°F outside, all that heat comes right into your unit.
  • If your intake air is at 110°F, you will struggle to get the compressed air you send downstream below 120°-130°F.
  • High compressed air temperatures will shorten the life of the oil and the compressor itself and increase all your costs. For every 10°F you operate the compressor above its normal operating temperature, the oil life is cut in half.
  • Because oil-free units do not use oil as a cooling agent (although gear oil floods the jackets in the airend to help cool the discharge air and keep the housing temperatures lower), keeping them cool is even more challenging.
  • There are several ways to get rid of that heat, including ventilation, forced air and water cooling.
  • No matter which cooling methods you use, you’ll need to adopt good maintenance practices to keep your system functioning properly.

Let Us Help

Elevated outdoor temperatures have a negative impact on air compressor efficiency. And thus, keeping temperatures under control in your rotary screw 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 dealing with high temperatures in your air compressor, get in touch with the experts at Kaishan. Contact us today.

sun icon
Random stat or
customer quote

textXXtext

text

Related posts

May 7, 2025

The Role Rotary Screw Air Compressors Play in a Disaster


Read more
April 30, 2025

Your Rotary Screw Compressor Airend: Where the Magic Happens


Read more
April 23, 2025

Ten Key Facts You Need to Know About Rotary Screw Air Compressor Motors


Read more
Connect with us and find what you need right now.



  • Industries
  • Products
  • Parts and service
  • Resources
  • About Us
  • Contact Us
  • Privacy Policy
  • Site Map
  • Home
  • Facebook
  • Linkedin
  • Vimeo
  • Youtube
Gary Sinise Foundation
Kaishan USA proudly supports the Gary Sinise Foundation
Kaishan
  • 15445 Industrial Park Drive, Loxley, AL 36551
  • (251) 257-0586
  • Copyright ©2025 Kaishan USA
  • All Rights Reserved.
Proudly assembled in Loxley, Alabama, USA
    ×
    Kaishan Product Configurator
      Model
     
      Drive
     
      Type
     
      Horsepower  
      Pressure
     
      Flow (25-3000)  
    Submit
      Models    
       
    ×
    Enter your name and email to see the webinar
      Full Name  
      Email  
       
    Submit