When auditing an installation, we look for solutions or alternatives to help our clients with 3 different aspects: Safety – Efficiency – Performance.
In the case of Recubec, our advice and changes were mainly focused on the energy efficiency aspect and performance.
Context of the case study
Transportation and residual material management
Since 1982, Recubec has developed advanced expertise in the management and transportation of hazardous and non-hazardous industrial waste.
“We use compressed air in many of our applications and production stages. Throughout the years, our conventional steel air piping system accumulated rust and became less and less performant. We did not have an adequate filtration system to treat the air exiting the compressor, and with time, contaminants and water vapors damaged our compressed air system.
The rust issue became so important that in some parts of the garage the air could no longer circulate or the air pressure at the outlet was very low due to the restricted diameter caused by rust.
This caused us multiple problems:
- Decreased productivity: Our mechanics’ impact tools could not operate at their full potential which caused work to slow down.
- Equipment replacement costs: The water in the air network was causing our equipment to rust. As a result, the equipment replacement costs soared as we had to replace it frequently.
- Safety issues: Mechanics had to use a hammer to knock on the air system so as to partially unclog the air system from the rust. This maneuver was not without risk and could have caused the system to burst.
We called upon Topring to diagnose the situation and propose solutions adapted to our needs. A single visit from a representative was enough to reveal that a great amount of rust had accumulated. Water was coming out of the quick couplers and of the compressor tank.
This water was mixed with rust and other contaminants. A Topring representative ran pressure tests at the different points of application and noted that there was a pressure differential greater than 10% between the compressor and the rest of the equipment.”
François Chrétien
Mechanical Supervisor, Recubec
Challenges and solutions
1. Aluminum piping system
To ensure that the compressed air is dry and clean, and that water and rust do not damage your tools and equipment; use materials that resist corrosion.
Aluminum is the most suitable material for compressed air systems because it offers numerous performance advantages (compared to more conventional air piping systems such as steel pipes or flexible hose assemblies). For optimum efficiency, opt for an aluminum air piping system.
The benefits of choosing an aluminum piping system vs a steel piping system:
| Aluminum Pipe | Steel Pipe |
|---|---|
| They resist corrosion and do not deteriorate | Traditional pipes rust and accumulate contaminants |
| Aluminum pipes allow air to circulate freely without friction | Rust causes friction and therefore air turbulence |
Topring PPS piping system is made of aluminum.
In addition to offering clean, top-quality air, Topring’s PPS air piping systems offer numerous advantages:
- Fittings offer high resistance to vibrations and impacts
- Quick and easy to assemble
- Leak-tight network and optimized flow rate which reduces pressure drops
- Modular design easily adapted and scaled to existing and future installations
- With a maximal operating pressure of up to 232 PSI
- Product certified in all Canadian provinces
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“We opted for Topring’s PPS aluminum network. It’s an innovative solution with many advantages. Since the materials are corrosion-resistant, there is no risk of accumulating rust. Our system is now leak-free, rust-free, and performant.” - F. Chrétien
2. Proper compressed air treatment
Compressed air contains water vapor and other contaminants which form an unwanted condensate. Compressed air must be filtered properly to ensure the elimination of downstream corrosion, reduce wear and tear, and increase the life span of pneumatic tools as well as that of the entire network. The most obvious place for this condensate to accumulate is in the compressor tank.
In addition to damaging the tank, this condensate will also be introduced into the airflow and be drawn into the compressed air network. Removing the condensate from the compressed air system is vitally important, as even small quantities can have a significantly detrimental effect on downstream equipment and reduce the air volume and quantity available.
Liters of water produced by a 25 HP compressor after 8 hours
| Ambient Air Temperature °C | % Humidity | ||||||||
| 20 % | 30 % | 40 % | 50 % | 60 % | 70 % | 80 % | 90 % | 100 % | |
| 49 | 84.5 | 126.8 | 169.1 | 211.4 | 253.7 | 296.0 | 338.0 | 380.1 | 422.8 |
| 43 | 64.1 | 95.5 | 126.8 | 159.6 | 190.1 | 222.3 | 253.7 | 286.4 | 317.8 |
| 38 | 47.7 | 70.9 | 94.1 | 118.7 | 141.8 | 166.4 | 189.6 | 212.8 | 237.3 |
| 32 | 35.6 | 51.8 | 69.6 | 87.3 | 105.0 | 121.4 | 139.1 | 156.8 | 174.6 |
| 27 | 25.9 | 38.2 | 50.5 | 62.7 | 76.4 | 88.6 | 101.0 | 113.2 | 126.8 |
| 21 | 17.7 | 27.3 | 35.5 | 45.0 | 54.5 | 61.4 | 72.3 | 81.8 | 90.0 |
| 16 | 12.3 | 19.1 | 25.9 | 31.4 | 38.2 | 45.0 | 50.5 | 57.3 | 64.1 |
| 10 | 9.5 | 13.6 | 17.7 | 21.8 | 27.3 | 31.4 | 35.5 | 39.6 | 45.0 |
| 4 | 5.5 | 9.5 | 12.3 | 15.6 | 17.7 | 21.8 | 24.5 | 27.3 | 30.0 |
| -1 | 4.1 | 5.5 | 8.2 | 9.5 | 12.3 | 13.6 | 16.4 | 17.7 | 20.5 |
| -7 | 2.7 | 4.1 | 5.5 | 6.8 | 7.7 | 8.6 | 9.5 | 10.9 | 12.3 |
| -12 | 1.4 | 2.3 | 3.2 | 3.6 | 4.5 | 5.5 | 6.4 | 6.8 | 8.2 |
“Having experienced numerous problems caused by the rust in our tools due to the presence of water and contaminants in our network, we’ve installed a filtration system to the compressor outlet. We added a water separator and a desiccant to the compressor outlet.” - F. Chrétien
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Water separatorWater separators use centrifugal separation to remove up to 99% of the water aerosol in compressed air. Working in conjunction with other compressed air treatment products, water separators are a cost-effective solution to ensure that bulk water generated in the compressed air is properly separated and discharged from the system.
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Desiccant air dryersA desiccant air dryer needs to be protected from oil by using a coalescent filter, which needs to be protected by a standard filter. These desiccant air dryers are therefore usually provided in 3-stage systems.
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Quick couplersTopring quick couplers offer many advantages compared to basic and traditional couplers; they are much more performant and resistant.
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Our experience with Topring
“I am very much satisfied with Topring’s expertise. This is a drastic change. The system’s pressure has increased everywhere in the garage, and the air is now both dry and clean. The network also has an aesthetic value which adds to our quality branding and professionalism.” - F. Chrétien
Useful links
Read our blog posts:
5 reasons to choose an aluminum compressed air pipe
5 solutions to remove and treat condensates