The core structure and working principle of Atlas Copco oil separators Structural composition
It is usually composed of a separator housing, an oil-gas separation filter element (the core component), an oil return pipe, a differential pressure indicator, etc.
Oil-gas separation filter element: It is mostly made of high-precision glass fibers or composite materials, and separates oil mist through interception, diffusion, and aggregation.
Atlas Copco oil separator housing: It withstands system pressure and provides space for the separation process. Some models have observation windows or oil drain valves.
Separation process
After the compressed oil-gas mixture enters the separator, it first undergoes a preliminary centrifugal separation (large oil droplets settle due to gravity and centrifugal force), and then passes through the fine filtration of the filter element (intercepting tiny oil mist particles). Clean air flows out from the center of the filter element, and the separated lubricating oil returns to the compressor main unit or the oil tank.
Main performance parameters
Atlas Copco oil separator separation efficiency: Original factory oil separators can usually control the oil content in compressed air at 1-3 ppm, meeting the needs of most industrial gas applications (such as pneumatic equipment, instrument gas, etc.).
Atlas Copco oil separator rated processing capacity: It matches the exhaust volume of the air compressor to ensure efficient separation at the designed flow rate.
Service life: Affected by working conditions, oil quality, air filter status, etc., it is generally recommended that the replacement cycle be 4,000-8,000 hours (specifically as per the equipment manual).
Common faults and impacts
Decreased separation efficiency
Filter blockage or damage causes the compressed air to have excessive oil content, polluting downstream equipment (such as dryers, pneumatic tools), and even affecting product quality.
Backflow of the oil return pipe or failure of the one-way valve, preventing the separated oil from flowing back, results in oil waste or insufficient oil in the main unit.
Excessive differential pressure
Filter blockage leads to an increase in the pressure difference before and after the separator, increasing energy consumption (for every 0.1 bar increase, energy consumption increases by approximately 1%), and in severe cases, may trigger protection shutdown.
Maintenance points
Regularly replace the filter element
Replace according to the manual cycle or replace when the differential pressure indicator shows a pressure difference exceeding the set value (usually 0.8-1.0 bar) promptly.
When replacing, clean the interior of the separator housing, check if the oil return pipe is unobstructed, and ensure the new filter element is well sealed (to avoid bypassing unfiltered oil gas).
Daily inspection
Observe if there is oil on the downstream pipelines to determine if the separation effect is normal.
Check the status of the differential pressure indicator, record the trend of pressure difference changes, and predict filter element blockage in advance.
Ensure the one-way valve of the oil return pipe is working properly to prevent reverse flow of lubricating oil during shutdown.
Related maintenance
Keep the air filter clean to reduce impurities entering the system and avoid accelerating oil separator contamination.
Use Atlas Copco's dedicated compressor oil to prevent oil deterioration and the formation of sludge that blocks the filter element.
