Condensate is the silent killer of your compressed air system, but we have systems in place to counter it. Treating this condensate is the next step to a healthy compressed air system. By adequately removing oil and debris from the condensate collected, it can be dumped directly into the ground and recycle the collected oil.
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Moisture, the silent killer of compressed air systems, is a threat we take seriously. That’s why we have robust condensate removal systems in place. We understand the importance of keeping your system free from this destructive element, and we’re here to help you do the same.
Because of the nature of compressed air, this condensation is an unavoidable part of the process. This condensate can be collected through drain valves into storage tanks to hold the condensate. You would then need to transport that contaminated water to a designated facility to take care of it properly. This method is inconvenient and expensive, making it a less-than-ideal solution for your condensate.
The more common alternative for condensate treatment is properly filtering the condensate so it is safe to dump into the sewage system. The oil and particulates are removed when the condensate passes through the different levels of filtration, and then it simply has to be dumped out into the sewer. Using this method, the oil-water separator will pay for itself by reducing the costs of disposing of wastewater.
Just because some people make it work without it doesn’t mean you should run the same risk. Condensate treatment is often viewed as an optional addition to compressed air systems, something helpful to have but can be done without. Don’t fall for this trap; it might seem easier, but you will end up with an even bigger mess later.
Condensation builds up slowly and destroys your system quickly. Operations can be going as expected, and the next thing you know, air is spilling out of your equipment, moisture is in your process, and money is lost. Everyone thinks it will never happen to them, so don’t let yourself fall into this trap with adequate condensate treatment.
As with compressors, oil-water separators can use different separation methods to remove contaminants from the condensate. These methods may vary in application, and depending on your system, this can cause different quantities of oil in the wastewater.
Four main types of oil separation are used:
Right now, those may seem like fancy descriptors for how the oil is being removed, so let’s explore them to understand the different types of separation.
Gravity Separation is the simplest method of oil removal. Acting upon the natural weight difference between water and oil, oil is lighter, so it will rise to the top and form a layer above the water. This allows for the oil to be skimmed off the top, but problems occur when the oil has become emulsified with the water.
Because some of the oil will make it through this process, the emitted wastewater may have a higher PPM of oil than is sufficient to meet the requirements for properly disposing of compressed air condensate.
Simply put, the media used for absorbing the oil is chemically attracted to oil and bonds with it while simultaneously repelling water. The oil becomes trapped in the filter media, and the water continues to be removed, even if it has become emulsified.
The wastewater that remains after this process meets the required PPM of oil and can, therefore, be dumped into the sewage system.
Rather than using a chemical bonding process to remove the oil, non-chemical adsorption relies on the material’s natural properties. It must be hydrophobic (water-fearing) and oleophilic (oil-loving). By attracting oil and repelling water, this style of absorption retains the oil within the material, and the water passes through to be disposed of in the sewage.
Adsorption and absorption are similar in name and process. With absorption, the condensate and oil are drawn into the center of the media. Meanwhile, adsorption keeps the oil on the surface of the material. The oil is attracted to the surface material and its many tiny pores to adsorb as much oil as possible while repelling the water.
The biggest benefit of having an oil-water separator is the improved removal of oil. When given enough time and space, oily wastewater will separate into two different layers. Oil, being lighter than water, will float to the top, and with a simple oil skimmer, it can be removed easily and efficiently.
Not only is it beneficial to remove the oil for environmental compliance, but removing the oil before the water has been treated or filtered it increases the effectiveness and lifespan of the treatment and filtration equipment. Removing this oil effectively can become a potential revenue generator if your reclaimed oil can be sold.
To learn more about Condensate Treatment, click here.
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