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What is a High Pressure Air Compressor?

Air compressors are a common machine frequently seen in the manufacturing industry to assist in the function of industrial plant, taking ambient air and compressing it to a pressurised state. From powering CNC machinery to hydraulics, air compressors are a universal piece of equipment. Most air compressors in factories operate in the low-medium pressure range.

However, when the pressure rating exceeds 10.4 bar, air compressors transition into high-pressure territory, with standard systems achieving an output of 69 bar to 414 bar. These high-pressure systems are not just for ancillary purposes; they are designed for a specialised range of applications. Read on to discover what sets these systems apart and why they are in such high demand.

How Do We Measure Air Compressor Performance?

How much force (pressure) you need and how fast you need it (airflow) are the two key performance measures. Both depend on the load from your machines, often differing for each buyer.

A Bar is a metric measure of force on an area. One bar is approximately the pressure you feel from the atmosphere at sea level – something you don’t notice day to day. It is equivalent to 14.5psi (pounds per square inch).

Meters cubed per hour (m3/h) or litres per second (l/s) are metric measures of how fast a compressor works, while CFM (cubic feet per minute) is the more recognised imperial measure. Pressurising air takes time, so a more powerful compressor is needed to deliver high volumes.

What Are High-Pressure Compressors Used For?

Air Tanks

One of the most prominent applications of high-pressure air compressors is in the scuba industry and emergency services. These compressors supply the breathing air for individuals operating in limited oxygen environments, such as scuba divers. With scuba tanks requiring a minimum of 200 bar, high-pressure air compressors are essential for this industry. These systems often feature an increased storage cylinder volume, a filling panel, and a breathing air module. Additional filtering of the air output is required to ensure the air is of a breathable quality.

Air Tightness & Leak Testing

For in-depth testing of components/systems that function requires retaining a sealed environment, such as valves to pipe systems, high pressure air compressors have the power to test if the components/systems can handle the pressure. Revealing any structural imperfections or weaknesses that could cause a leak or prevent optimal functionality. Another additional system that may be tested in this manner includes pneumatic & hydraulic systems, which rely on pressurised substances such as water, oil, air & gases to work.

Chemical & Petrochemical Industry

Critical to many chemical and petrochemical industry core processes, high pressure air compressors are needed to power the automated systems from process cooling to pneumatic conveying. It is essential for more specialised/delicate processes such as catalytic cracking or transport of high-viscosity fluids. Breathable quality air output can often be preferred to ensure a safe work environment and prevent contamination.

The Importance of Breathing Air

For air to be considered breathable, the output air of a compressor needs to be purified during the stages of compression to control the level of contaminants. This can be achieved by having a high pressure system designed for pure air or fitted with a filter/module to purify the compressed air.

For applications where the air is breathed in or sensitive to contamination, it is a highly desirable feature for high pressure air compressors.

What is a High-Pressure Air Compressor Made Up Of?

The fundament features of a high pressure air compressor include:

Multi-Stage Piston Compressor - The pistons pressurise the air in multiple stages. The number of pistons is reflective of the pressure rating output. A 3 to 4 piston system would have an output of around 300 bar.
Multistage Intercooler - To counteract the heat built up between stages, this cooling and condensation system cools the air to a temperature that retains optimum pressure capabilities.
Storage Tanks/Cylinders - The storage capacity for the produced compressed air, compressor tanks retain the pressure of compressed air inside while providing storage solutions for additional air supplies without having to turn on the compressor, save wear on the compressor and remove condensation from the air.

What is the difference between a Standard High Pressure Air Compressor & a Booster Model?

While most typical high-pressure air compressors include the core features above, high-pressure booster systems are another type of high pressure air compressor that uses boosters to cater to specific pressure outputs.

Seen in systems that may have multiple functions or are connected to multiple machines, the boosters are a cost effective way to increase the pressure rating for specific outputs rather than investing in a new compressor. They are a popular feature in more industrial environments for production processes that get their compressed air from one compressor.

Industrial Surplus Clearance Opportunity

The systems that supply high pressure air are not off the shelf bits of kit. These quality systems are typically built to order with lead time easily being 8 months and up, so if you’re in the market to buy one now, you’re in luck.

In an exclusive clearance event for a pair of Bauer Kompressoren 340 Bar Air Compressors for a fraction of the price new, these current model and like new compressors have the power to provide very high pressure levels nearer the top end of the compressed air scale.

Find out more about these at Bauer High Pressure Compressors and skip the lead time by contacting Helen from our surplus clearance team at [email protected].

Bauer Kompressoren High Pressure Air Compressor Cell

Bauer Kompressoren High Pressure 340 Bar Multi-Stage Reciprocating Air Compressor

Bauer multi-stage, very high pressure air compressor as new with less than 20 hours running time. Including compressor block, electric motor, switch box and control, pressure maintaining and isolation valves, automatic condensate drain, air intake filter, and oil and water separator. A fully enclosed acoustic room is also included.

Stock No: AC197S
Category: Air compressors
Model: Bauer Kompressoren l 28.0-75-l
Year of Manufacture: 2016
CFM/Kw: 260CFM // 75kW
Compressor Type: Multi-stage continous-duty reciprocating
Other Info: C/W Acoustic room (4400 x 2850 x 2250mm)
Condition: Excellent Condition, Ex demonstration, Current Model
Direct Site Clearance Price [?]: £ Login or Register for price.
Part of a Direct Site Clearance: Bauer High Pressure Compressors