In any compressed air system, it is crucial to prioritise heat removal and moisture reduction as the first steps. Effective cooling safeguards downstream equipment—such as dryers and filters—and ensures your system operates efficiently. Do you need an aftercooler?
At National Filters, we provide two types of aftercoolers: water-cooled (ACW series) and air-cooled (ACA series). Below is an overview of how each type functions and their ideal applications.
Water-Cooled Aftercoolers (ACW Series)
The ACW series employs a counter-flow design. Hot compressed air travels through the tubes while cooling water flows around them in the opposite direction. This direct contact allows for efficient heat transfer, often cooling to just a few degrees above the water inlet temperature.
- How it functions: Compressed air inside the tubes exchanges heat with the cooling water outside. The counter-flow mechanism maximizes temperature reduction.
- Primary Advantage: Highly effective in high-heat applications, as water can remove more heat than air.
- Best use: Suitable for industries with existing water chillers or cooling towers, such as automotive plants, food and beverage production lines, petrochemical sites, and electronics facilities.
Water-cooled aftercoolers are particularly advantageous in situations where space or ambient heat renders fan-based cooling inadequate. With the ACW series, you can protect sensitive downstream equipment even in hot or confined environments.
Air-Cooled Aftercoolers (ACA Series)
The ACA series utilizes a high-efficiency axial fan to draw ambient air over copper tubes fitted with aluminium fins. Hot compressed air enters these tubes, releases heat, and exits at approximately 10 °C above the surrounding air. This straightforward design effectively lowers temperature and dew point without requiring additional utilities.
- How it functions: Compressed air flows through copper tubes while the fan moves outside air across the fins, facilitating heat removal.
- Primary Advantage: Operates without the need for water or other cooling media—only electricity for the fan is required.
- Best use: Ideal for general compressed air systems in locations where water is limited or adding a water circuit is impractical.
By lowering the air temperature early on, the ACA aftercooler enhances the performance of refrigeration or adsorption dryers and downstream filters. Cooler air retains less moisture, allowing dryers to operate more efficiently and prolonging their lifespan.
Choosing the Right Aftercooler
- Available utilities: If you have chilled water or a cooling loop, the ACW series offers superior cooling. If you lack water infrastructure, opt for the ACA series and utilize ambient air.
- Ambient conditions: In hot, dusty, or cramped environments, air-cooled units may struggle. Water cooling provides more reliable cooling in high ambient temperatures.
- Maintenance needs: Air-cooled aftercoolers require cleaning of fans and fins, while water-cooled models necessitate water treatment and periodic tube inspections. Choose based on your maintenance capabilities.
- Space constraints: Air-cooled units require adequate space for airflow around the fins, while water-cooled units can be more compact if positioned near existing piping.
Maintaining Your Aftercooler
Regardless of the model you select, regular maintenance is key to ensuring optimal performance. For ACA units, check fans and filters, while for ACW units, inspect water quality and tube integrity. Additionally, monitor inlet/outlet temperatures and dew points. Early detection of fouling or corrosion helps prevent energy waste and system downtime.
No matter which model you choose, effective heat removal will enhance the longevity of your air treatment components and reduce energy consumption. Contact National Filters today to explore which aftercooler best suits your system and how we can assist in optimising your compressed air setup for reliability and efficiency.
Click on the link for National Filters Aftercooler range as well as technical data https://nationalfilters.com.au/product-category/air-dryers-aftercoolers/aftercooler/