Intercoolers

Intercooler ; if you understand that inter means between, and that cooler - well that's self explanatory isn't it? Particularly if you're inclined to a cold beverage drawn from a cooler on a hot afternoon out on the beach, then you already understand intercoolers.

The process of compressing air elevates the air temperature, sometimes to quite high temperature levels. As air is compressed from single cylinder or from cylinder to cylinder in twin cylinder, two stage reciprocating compressors, or from rotary screw compressors, , or vane type compressors and then into the receiver, the temperature of the compressed air will continue to rise.

In a multi-stage unit compressor, the air is compressed in succeeding cylinders, getting hotter and hotter along the way.

An intercooler will be installed between the cylinders to help cool the air before it is ingested into the next cylinder for further compression. This aids in the compressor's efficiency.

Air Inter Coolers

Intercoolers in multi-stage units may function through air cooling or water cooling.

In air cooling the compressed air will pass through a chamber, on the outside of which, is substantially increased surface area - sometimes called fins - exposed to the ambient environment. The increased surface area will allow the heat inside the compressed air line to move more readily to the surface and to escape into an area of lower temperature.

Water Inter Coolers

Water cooling is achieved by passing the compressed through water-cooled heat exchanger(s) , similar in concept to the one shown on the linked page.

Cool water will flow around the outside of the air line, quickly taking heat away, and cooling the compressed air rapidly.

Air Tank Coolers

Consider also that the air receiver, that tank that stores your compressed air before use, and that is located between your compressor and your plant air lines, is also an intercooler of sorts. The longer the air sits in the tank receiver before use, the cooler the air will get and the more condensation will take place in the receiver.

That, and frequent voiding of collected water through the receivers auto drain or manual tank drain will prevent this condensed water from entering the downstream airline, benefitting all downstream air components that are negatively affected by water.