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Air Compressors for Chemical Industry
In chemical manufacturing, compressed air isn’t a luxury; it’s the fourth utility, just like electricity, gas, and water. The quality and dependability of your compressed air have a direct effect on your product purity, your safety and the efficiency of your processes. If it stops, it’s not just a minor nuisance – it’s a process-critical failure that can lead to expensive downtime, safety hazards and lost batches.
- Atlas Copco Premier Distributors
- 50 Years Experience
- ISO 9001, 14001 and 45001
- 24/7 emergency support
The Critical Difference: Energy Air vs. Active Air in Chemical Processes
Not all compressed air serves the same function. Understanding the distinction between Energy Air and Active Air is the foundation of proper system design.
Energy Air powers equipment. It performs mechanical work, driving pneumatic tools, conveyor systems, and actuators on control valves. While its quality is essential for equipment protection, it does not come into contact with the product.
Active Air is part of the process. It touches the product directly, for example for aeration, pneumatic conveying or drying. The air quality is critical, because it directly influences the quality of the final product.
This guide will take you through the essential design, compliance and maintenance considerations to help you specify a compressed air system that delivers Class 0 purity, protects your process and is compliant with UK regulations for the chemical sector.
50
Years Experience
Why Air Purity Matters: Understanding ISO 8573-1 Standards for Chemicals
Particles, water and oil can all have detrimental effects in chemical applications. Contamination can cause product spoilage, unplanned downtime and damage to your brand reputation. The global standard for compressed air purity is ISO 8573-1:2010. It breaks down contaminants into three classifications:
- Solid Particles: Dust, rust, microorganisms
- Water: Pressure Dew Point (PDP) is the temperature at which vapour turns into liquid
- Total Oil: Liquid, aerosol and vapour
For critical chemical processes where contamination risk is highest, only the most stringent purity classes for oil content are acceptable:
- ISO Class Oil Content (mg/m³) Application Example
- Class 1 ≤ 0.01 Energy Air, general process use
- Class 0 User-defined, stricter than Class 1 GMP, Active Air, direct product contact
Specifying certified Class 0 oil-free air isn’t just good practice—it’s the ultimate insurance policy for safety, quality, and regulatory compliance. Regular Compressed Air Quality Testing verifies that these standards are consistently met.
Selecting the Right Oil-Free Compressors for the Chemical Industry
The most critical technology decision is between a certified oil-free design and a system that relies on filtration. Tip There is no compromise on the Active Air application for certified oil-free air for a reason, it is an absolute requirement against contamination.
Certified Oil-Free Compressors
Certified Oil-Free Compressors
Engineered so that no oil ever enters the compression chamber. This design eliminates the risk of contamination and is the only way to guarantee Class 0 air purity.
“Technically Oil-Free” Systems
“Technically Oil-Free” Systems
Use an oil-injected compressor with downstream filters to remove oil. This carries an inherent risk of catastrophic contamination if a filter element fails.
Rotary Screw Compressors (ZR/ZT Series)
Rotary Screw Compressors (ZR/ZT Series)
Control Gear recommends Atlas Copco’s industry-leading oil-free technologies for chemical applications:
These Class 0 certified workhorses are built for 24/7 reliability.
Centrifugal Compressors (ZH Series)
Centrifugal Compressors (ZH Series)
Ideal for large-scale facilities, these machines provide exceptional energy efficiency for high, stable baseload air demand. For more detail, read Centrifugal Compressors – Everything You Need to Know.
Variable Speed Drive (VSD)
Variable Speed Drive (VSD)
For processes with fluctuating air demand, Variable Speed Drive (VSD) is essential. Atlas Copco’s VSD technology reduces energy use by up to 35–50% by precisely matching air output to plant demand, making it ideal for chemical processes with variable loads. With energy representing over 70% of a compressor’s lifecycle cost, VSD technology offers one of the fastest returns on investment in chemical plant optimisation. Explore the differences in our guide on Oil Versus Oil-Free Air Compressors.
Engineering a Complete System for Peak Performance
Air Treatment: Dryers and Filtration
Removing water vapour is vital to prevent corrosion and product contamination. The choice between refrigerated dryers (for a +3°C PDP) and desiccant dryers (for PDPs as low as -70°C) depends on the application’s specific needs. Incorrect dryer selection is one of the most common causes of system inefficiency or moisture-related contamination in chemical plants.
In tandem with drying, multi-stage filtration is essential to remove particulates, oil aerosols, and vapours. A typical system includes pre-filters, high-efficiency coalescing filters, and activated carbon filters, designed to meet ISO 8573-1 Class 1 or Class 0 air standards.
Distribution Pipework
The pipework delivering air must not introduce contaminants. While traditional galvanised steel corrodes over time, modern alternatives prevent this. Aluminium systems like Atlas Copco’s AIRnet are chemically inert and corrosion-resistant—ideal for harsh process environments.
Remote Monitoring and Predictive Maintenance
In contemporary systems, intelligent monitoring is harnessed to optimise uptime. Atlas Copco’s SMARTLINK monitoring system offers real-time insights into the health of your system. It is a remote monitoring solution that facilitates predictive maintenance and immediate notifications of pressure drops, filter obstructions or unusual operating trends.
50 Years Experience
Why Work With Us?
- One of the largest independent Fluid Power companies operating in the United Kingdom
- Atlas Copco Premier Distributors
- Diverse Market Coverage including 9 key specialisms
BOOK YOUR CHEMICAL INDUSTRY AIR COMPRESSOR CONSULTATION TODAY
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Your Partner for Compliant & Efficient Compressed Air
Control Gear has been offering leading-edge compressed air expertise to the industrial sectors throughout South Wales, Mid Wales, West Wales and the West Country for over 50 years. We are an Atlas Copco Premier Distributor and are accredited to ISO 9001, 14001 and 45001 standards. We offer a complete service from system design and installation to preventive maintenance and 24/7 emergency support.
- Visit us Heol Groeswen, Treforest Industrial Estate, Pontypridd, Rhondda Cynon Taff, CF37 5YF
- Call us 01443 843126
- Email us enquiries@control-gear.com
Mon–Fri · 09:00–17:00
24/7 emergency call-out available
Compressed Air System Design Checklist
- Oil-Free Compressor (Class 0)
- Desiccant Dryer (PDP ≤ -40°C)
- Multi-Stage Filtration
- SMARTLINK Monitoring
- DSEAR/ATEX-compliant components
- PSSR-compliant documentation
Looking to optimise your air system for chemical production?
Our turnkey systems help ensure your chemical manufacturing process is safe, compliant and efficient.
Contact Control Gear for a site survey, risk assessment, or compressed air audit.
A compressed air system in a chemical plant is a critical asset. Its design and maintenance demand a strategic approach focused on absolute purity, guaranteed compliance, and total energy efficiency. Partnering with an expert provider is the most effective way to manage risk and ensure your fourth utility is a source of reliability, not a liability.
Speak with our technical team to book a compliant air system design consultation, risk assessment, or audit tailored to your chemical facility.
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