Air compressor intercoolers are the most common type, both in factory forced induction cars and aftermarket. They are technically simple, rugged and reliable. An air/air intercooler consists of a tube and fin radiator. The induction air passes through thin rectangular cross-section tubes that are stacked on top of the other. Often inside the tubes are fins that are designed to create turbulence and so improve heat exchange. Between the tubes are more fins, usually bent in a zigzag formation. Invariably, air/air intercoolers are constructed from aluminium. The induction air flows through the many tubes. The air is then exposed to a very large surface area of conductive aluminium that absorbs and transfers the heat through the thickness of metal. Outside air – driven through the core by the forward motion of the car – takes this heat away, transferring it from the intake air to the atmosphere.
An air compressor intercooler is any mechanical device used to cool a fluid, including liquids or gases, between stages of a multi-stage heating process, typically a heat exchanger that removes waste heat in a gas compressor. They are used in many applications, including air compressors, air conditioners, refrigerators, and gas turbines, and are widely known in automotive use as an air-to-air or air-to-liquid cooler for forced induction (turbocharged or supercharged) internal combustion engines to improve their volumetric efficiency by increasing intake air charge density through nearly isobaric (constant pressure) cooling.


Air compressor intercooler
http://air compressor intercooler heat exchanger

Benefits of Air Compressor intercooler :

  1. air blast heat exchangers are as no hydraulic system can convert mechanical to hydraulic energy with 100% efficiency, heat is always going to be produced in the system as a by product.
  2. This means there will be a rise in the oil temperature that must be controlled in order to optimise the performance of your system.
  3. As the temperature of the oil rises, its viscosity drops and the oil will lose its lubricating properties. This can affect seals and ‘O’ rings and can ultimately damage the whole system. At best the oil will have to be changed frequently at considerable cost.

Features Of Air compressor intercooler:

  1. Cooler core easily removable for cleaning of fins
  2. Impeller/motor arrangement are housed and protected inside a ducting
  3. Cooler core all steel welded construction and hot dip galvanise
  4. Very high fatigue strength and pressure resistance
  5. Metallic bond between tubes and fins assures excellent heat transfer and rigidity of fins
  6. High quality standards.

Advantages Of Air Compressor intercooler:

  1. ‘Long life’ aluminium core
  2. 20 bar working pressure
  3. Single phase 230 V AC 50 Hz
  4. Three phase 230/400 V AC 50/60 Hz 12 – 24 V
  5. Hydraulic Gr.1 – Gr.2 – Gr.3
  6. Cooling capacity up to 2.75 kW/°C
  7. Flow rate 5 to 520 l/min
  8. Optional: fixed thermostat gauged as per request or adjustable thermostat 0:120°
  9. Reduced running costs against water
  10. No danger of cross-contamination
  11. No secondary coolers required (cooling tower)
  12. Very low maintenance and installation cost
  13. High lifespan.

Applications :

  1. Charge air coolers
  2. Alternator air coolers
  3. Boiler feed pump heaters/coolers
  4. Diesel generator air coolers
  5. Gas circulator motor air coolers
  6. Generator air coolers
  7. Heating coils
  8. Main engine charge air coolers
  9. Motor air coolers
  10. Scavenge air coolers
  11. Waste heat recovery units