What Is Compressed Air Condensate?
Compressed air systems are crucial to a broad range of industries, from automotive to aerospace. As your system compresses the air, its water vapour can turn into condensation. If too much of this condensation makes its way through your system, it causes wear and tear to your equipment connected to it. You also risk reducing the quality of your end products or services.
In oil-injected compressors, the condensate can also contain minuscule oil droplets. These contaminants may be invisible to the naked eye, but they can wreak havoc on your equipment and the environment if handled or disposed of incorrectly.
Whether you use an oil-injected or oil-free air compressor, high moisture levels can and will degrade your equipment and potentially even put you at risk of breaking the law. This guide will tell you exactly what condensate is, how it forms, the risks of neglecting it, and what you can do about it. We will also discuss the many benefits of properly dealing with compressed air condensate.
At Search Air, we have been an industry-leading supplier and installer of compressed air systems for over 75 years. If you need a compressed air audit, we are only a phone call away – condensate and contamination are just some of the costly and dangerous issues we can identify. Alternatively, we also supply a range of the most advanced Atlas Copco solutions available, equipped with sophisticated water and oil separators that can minimise the risks associated with condensate while improving efficiency and productivity in your workplace.
Call us today to learn more about our energy-saving solutions. Keep reading to learn everything you need to know about compressed air condensate.
Understanding Compressed Air Condensate
Oil-injected compressors release condensate that mostly contains water but can also contain microscopic contaminants and oil particles. So, where does this water come from?
Ambient air in the atmosphere contains a certain amount of moisture, which makes its way into your compressor as the air is pulled into the system through the inlet valve. Moisture in air turns into condensate when it reaches a certain temperature, known as the pressure dew point (PDP). When air reaches the PDP, it can no longer hold water vapour and turns into a liquid state called condensation.
In air compressors, the compression process also causes the air to release condensate in addition to the heating process. For example, if your system works at a pressure of 7 bar(e), it reduces the incoming air to seven-eighths of its original volume, reducing the air’s ability to hold moisture by seven-eighths. Your compressor is fitted with equipment to release this moisture but can rarely eliminate 100% of it.
The amount of condensate released by a compressor is surprisingly high. A 100 kW system operating at 20 degrees Celsius and 60% humidity can release around 85 litres of water over eight hours. The higher the air temperature, the more condensate is produced. For example, a 55 kW compressor operating at 24 degrees Celsius with 75% humidity can produce up to 280 litres daily.
By law, you are required to remove, manage, and dispose of this condensate responsibly. Fortunately, properly managing condensate is advantageous for more reasons than just compliance.
What Is Compressed Air Condensate?
Why Is Condensate Management Important?
Responsible condensate management is crucial for a host of reasons, namely:
Environmental Impact
Condensate can contain microscopic traces of contaminants such as oil that, while not visible, can damage the environment. If discharged without first being treated, condensate from compressors can reduce soil quality, contaminate water supplies, and even harm local habitats.
Equipment Longevity
Poor condensate management can lead to too much moisture working its way through your compressed air system, which can lead to corrosion not only of the system itself but also of all the tools and equipment connected to it.
Energy Efficiency
Mismanaged condensate can reduce the efficiency of your air systems, often causing users to increase pressure levels to achieve their desired result. Consequently, they unnecessarily spend an arm and a leg on energy bills.
Compliance
Businesses in heavy industries must comply with stringent regulations to protect the environment. Standards such as ISO 8573 set out minimum requirements for air purity, including the safe removal and correct treatment of condensate. Compliance issues can result in fines of tens of thousands of pounds, which could tarnish a company’s reputation and consume a significant chunk of its revenue.
How to Manage Compressed Air Condensate
The best way to find out how to properly manage condensate is to contact our experts for an audit. Here is what you can do in the meantime:
Inspect Your System
Start by visually inspecting your system as condensate drains to see where it is being directed. Make sure to check all the compressors, dryers, air receivers, and filters. If your condensate is simply being directed to the floor or into simple containers, you will need to treat the water before you can dispose of it to comply with the law.
Install Oil and Water Separators
Ideally, the condensate from your compressed air system should be piped into a water separator (some separators can also effectively separate oil and other contaminants from the water). These separators treat the condensate so that it can be simply drained into the foul water drain (NOT the rainwater or stormwater drains) without harming the environment. Remember that you may need permission from your local water authority before draining your treated condensate.
Learn More about Compressed Air Condensate Management
If you need new oil/water separators to keep your systems in full working condition and your business on the right side of the law, we can help. At Search Air, we have been a leading supplier of advanced compressed air equipment for the better part of eight decades. We were also named the Atlas Copco Distributor of the Year in 2022, so you can trust us for honest advice and recommendations. Call us today to learn more about our effective and efficient separators. Unsure what you need? Book an audit at a time that works with your busy schedule.