Condensate Treatment
A wide range of condensate treatment technologies
Correctly discharging and disposing of the condensate which occurs in a compressed air network is a critical part of keeping the network functioning properly and at the the correct network pressure. This all too often overlooked part of the process is essential to keep the network running at peak efficiency, this section explains the role of the condensate drain in the compressed air network.
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As we have seen, compressed air contains impurities such as water, oil and tiny particles which occur naturally in the air around us or which are introduced into the air stream by the compression process, like rust and pipe scale. CompAir air treatment products remove these impurities, air dryers, use different technologies to dry the air & remove the water vapour and air filters, remove solid particles.
Once water and particles are removed from the airstream, it's the job of the condensate drain to drain away this condensate mixture so that it can be disposed of in the correct way. The condensate is usually drained into an oil/water separator so that the oil can be disposed of correctly. Only then is the compressed air ready to be used by the production process. The condensate drain is a special type of valve which can run in a variety of ways depending on the type of installation. For example the drain can be set to run on a timer to drain the condensate away at defined intervals, unpowered drains can work without a power source, a compressed air energy saver can be connected to say a light switch which will shut the drain off when the lights are switched out at the end of a shift to avoid pressure losses (read more below).
Our electronic condensate drains are designed to work for compressed air and industrial gases too. They are especially and significantly designed to work in conjunction with compressed air filters, refrigeration dryers, wet air receivers and after coolers to reduce compressed air leaks.
left to right: the air compressor, air tank or receiver, immediately to the right of the tank on the floor is a condensate drain to drain the condensate from the air tank. To the right of this is the air dryer to remove the moisture from the compressed air, both drain and dryer are connected to the oil/water separator on the far right.
CTDV & CTDC
The CTDV timer controlled condensate drain is a combination of a solenoid valve and an electronic timer designed to automatically remove condensate from compressed air systems. The CTDC in addition, has an integral ball valve and a strainer, all in the same body, please download the brochure under the downloads tab for full product specifications.
Max. compressor capacity: Any size
Min./max. system pressure Standard: 0 - 16 bar, HP: 0 - 80 bar
CCNL10 & 100
Electronic zero air loss drain with alarm feature - The CCNL10 removes all types of condensate from compressed air systems with air flow up to 10 m3/min without the loss of compressed air while the CCNL100 up to 100 m3/min.
Max. compressor capacity: CCNL10: 10 m3/min, CCNL100: 100 m3/min
Min./max. system pressure: 0 - 16 bar (0 - 230 psi), HP: 0 - 50 bar (0 - 725 psi)
CMNL10, 100 & 500
Magnetically operated level sensed condensate drain - the CMNL10 is a magnetically operated zero air loss drains that discharge condensate from all compressed air systems by using a unique technology based on magnetic forces and without the usage of electricity. The environmentally-friendly CMNL100 removes all types of condensate from compressed air systems up to 100 m3/min while the CMNL500 is ideal for larger applications up to 500 m3/min with exceptionally large condensate discharge capacity of 4,800 l/h at 16 bar.
Max. compressor capacity:
CMNL10: 10 m3/min
CMNL100: 100 m3/min
CMNL500: 500 m3/min
Min./max. system pressure: 0 - 16 bar (0 - 230 psi)
CSLV & CSLVE
Compressed air energy saver - a typical compressed air system has air losses through pipe works connections. By installing an CSLV the end user will limit them. Typically installed in the compressed air line after the air receiver.
The CSLV has proven its worth and saved millions m3 of compressed air around the world, helping end users to save valuable compressed air from escaping unnecessarily, reducing compressor running hours and thus extending its lifetime, saving energy and operating costs. The CSLV can be installed in all pipeline systems of 1" or 2". When the ball valve of the CSLV is closed, all compressed air will remain in the air receiver, rather than being lost through leakages.
Please download the brochure under the downloads tab for full product specifications.
There is great flexibility in having these drains available as stand-alone equipment. They can be installed quickly as and when needed and they require very little maintenance. However, condensate draining equipment should not be considered as an optional afterthought. It is more than a nice feature to have in a well equipped air compressor set-up. The best compressed air system, comprising of the highest quality compressors, dryers and filters, still needs to have the condensate discharged.
Without condensate treatment, your compressed air system can end up providing an inconsistent supply of dry air. With condensate, there is a high likelihood of production problems occurring. This can include rust and corrosion and in cold weather there is the possibility of freezing.
It also happens that during the process of compressing air, the condensate is compressed and discharged at elevated temperatures in a saturated state. As the air cools through aftercoolers, dryers, or pipelines, the steam condensate turns into a liquid form which then mixes with any normal oil carryover from the compressor. The condensate becomes contaminated by the oil and must be treated before expelling it into a sewer system or onto the ground. The oil must be separated from the condensate and only the condensate can be expelled. The oil must be reclaimed and disposed of in an environmentally safe manner.
In every compressed air system, water is the single largest contaminant and often the most obvious. Removing this liquid condensate from the system can be a high energy consuming area if not managed correctly, so we have different products available to meet your commercial needs which minimize any air losses, and which can be tailored to any compressed air network, the end result is saving money.
Please download the product literature under the downloads tab for the full technical details of each CompAir condensate drain range.
New Serviceable Oil / Water Separator designed for smaller compressor installations
- Compressor capacities up to 2 m3/min
- Efficient on-site disposal of compressed air condensate
Oil/Water Separators
As explained above, any compressed air system produces condensate mixed with oil and other substances. These condensates are removed from the system through purges to prevent them from reaching the point of consumption. This condensate mixture is piped into an oil / water separator as shown in the image (left and above) to filter the condensate in order to dispose of the water and retain the oil with particles in a container to be properly recycled and avoid environmental pollution.
The separator ensures proper filtration of the condensate & reduces operational costs overall. Companies have the legal responsibility to duly manage the contaminated waste.
It is mandatory by European laws. e.g. Spain has the dedicated “Law of Environmental Responsibility 26/2007” that stablishes fines for those companies who fail to manage the residues and contaminate the environment.
Please download the brochure under the downloads tab to see all the models available.
Condensate Drains
As we have seen, compressed air contains impurities such as water, oil and tiny particles which occur naturally in the air around us or which are introduced into the air stream by the compression process, like rust and pipe scale. CompAir air treatment products remove these impurities, air dryers, use different technologies to dry the air & remove the water vapour and air filters, remove solid particles.
Once water and particles are removed from the airstream, it's the job of the condensate drain to drain away this condensate mixture so that it can be disposed of in the correct way. The condensate is usually drained into an oil/water separator so that the oil can be disposed of correctly. Only then is the compressed air ready to be used by the production process. The condensate drain is a special type of valve which can run in a variety of ways depending on the type of installation. For example the drain can be set to run on a timer to drain the condensate away at defined intervals, unpowered drains can work without a power source, a compressed air energy saver can be connected to say a light switch which will shut the drain off when the lights are switched out at the end of a shift to avoid pressure losses (read more below).
Our electronic condensate drains are designed to work for compressed air and industrial gases too. They are especially and significantly designed to work in conjunction with compressed air filters, refrigeration dryers, wet air receivers and after coolers to reduce compressed air leaks.
left to right: the air compressor, air tank or receiver, immediately to the right of the tank on the floor is a condensate drain to drain the condensate from the air tank. To the right of this is the air dryer to remove the moisture from the compressed air, both drain and dryer are connected to the oil/water separator on the far right.
CTDV & CTDC
The CTDV timer controlled condensate drain is a combination of a solenoid valve and an electronic timer designed to automatically remove condensate from compressed air systems. The CTDC in addition, has an integral ball valve and a strainer, all in the same body, please download the brochure under the downloads tab for full product specifications.
Max. compressor capacity: Any size
Min./max. system pressure Standard: 0 - 16 bar, HP: 0 - 80 bar
CCNL10 & 100
Electronic zero air loss drain with alarm feature - The CCNL10 removes all types of condensate from compressed air systems with air flow up to 10 m3/min without the loss of compressed air while the CCNL100 up to 100 m3/min.
Max. compressor capacity: CCNL10: 10 m3/min, CCNL100: 100 m3/min
Min./max. system pressure: 0 - 16 bar (0 - 230 psi), HP: 0 - 50 bar (0 - 725 psi)
CMNL10, 100 & 500
Magnetically operated level sensed condensate drain - the CMNL10 is a magnetically operated zero air loss drains that discharge condensate from all compressed air systems by using a unique technology based on magnetic forces and without the usage of electricity. The environmentally-friendly CMNL100 removes all types of condensate from compressed air systems up to 100 m3/min while the CMNL500 is ideal for larger applications up to 500 m3/min with exceptionally large condensate discharge capacity of 4,800 l/h at 16 bar.
Max. compressor capacity:
CMNL10: 10 m3/min
CMNL100: 100 m3/min
CMNL500: 500 m3/min
Min./max. system pressure: 0 - 16 bar (0 - 230 psi)
CSLV & CSLVE
Compressed air energy saver - a typical compressed air system has air losses through pipe works connections. By installing an CSLV the end user will limit them. Typically installed in the compressed air line after the air receiver.
The CSLV has proven its worth and saved millions m3 of compressed air around the world, helping end users to save valuable compressed air from escaping unnecessarily, reducing compressor running hours and thus extending its lifetime, saving energy and operating costs. The CSLV can be installed in all pipeline systems of 1" or 2". When the ball valve of the CSLV is closed, all compressed air will remain in the air receiver, rather than being lost through leakages.
Please download the brochure under the downloads tab for full product specifications.
There is great flexibility in having these drains available as stand-alone equipment. They can be installed quickly as and when needed and they require very little maintenance. However, condensate draining equipment should not be considered as an optional afterthought. It is more than a nice feature to have in a well equipped air compressor set-up. The best compressed air system, comprising of the highest quality compressors, dryers and filters, still needs to have the condensate discharged.
Without condensate treatment, your compressed air system can end up providing an inconsistent supply of dry air. With condensate, there is a high likelihood of production problems occurring. This can include rust and corrosion and in cold weather there is the possibility of freezing.
It also happens that during the process of compressing air, the condensate is compressed and discharged at elevated temperatures in a saturated state. As the air cools through aftercoolers, dryers, or pipelines, the steam condensate turns into a liquid form which then mixes with any normal oil carryover from the compressor. The condensate becomes contaminated by the oil and must be treated before expelling it into a sewer system or onto the ground. The oil must be separated from the condensate and only the condensate can be expelled. The oil must be reclaimed and disposed of in an environmentally safe manner.
In every compressed air system, water is the single largest contaminant and often the most obvious. Removing this liquid condensate from the system can be a high energy consuming area if not managed correctly, so we have different products available to meet your commercial needs which minimize any air losses, and which can be tailored to any compressed air network, the end result is saving money.
Please download the product literature under the downloads tab for the full technical details of each CompAir condensate drain range.
Oil and Water Separators
New Serviceable Oil / Water Separator designed for smaller compressor installations
- Compressor capacities up to 2 m3/min
- Efficient on-site disposal of compressed air condensate
Oil/Water Separators
As explained above, any compressed air system produces condensate mixed with oil and other substances. These condensates are removed from the system through purges to prevent them from reaching the point of consumption. This condensate mixture is piped into an oil / water separator as shown in the image (left and above) to filter the condensate in order to dispose of the water and retain the oil with particles in a container to be properly recycled and avoid environmental pollution.
The separator ensures proper filtration of the condensate & reduces operational costs overall. Companies have the legal responsibility to duly manage the contaminated waste.
It is mandatory by European laws. e.g. Spain has the dedicated “Law of Environmental Responsibility 26/2007” that stablishes fines for those companies who fail to manage the residues and contaminate the environment.
Please download the brochure under the downloads tab to see all the models available.