Condensate Combustion

Abstract

The condensate treatment system includes a separator for separating condensate from the airflow exiting the compressor, a heat exchanger for heating the separated condensate, an evaporative heater for evaporating the heated condensate exiting the heat exchanger, and a vent tube in which the evaporated heated condensate mixes with the cooling airflow exiting the compressor.

Description

[Technical field]

[0001] The present disclosure relates generally to portable air compressors, and more specifically to a condensate treatment system integrated into a portable air compressor. [Background technology]

[0002] There are recovery systems in the prior art that recover condensate in stationary compressor systems.

[0003] However, conventional condensate recovery systems are not used with portable compressors, which imposes certain costs on the customer to recover and dispose of the condensate.

[0004] Therefore, there is an unmet need for a condensate management system for portable compressors that use exhaust air streams.

[0005] The present invention is directed to a compact compressor and condensate treatment system mounted in a compressor package that occupies less floor space and makes the proposed integrated system more portable compared to conventional systems. Summary of the Invention

[0006] The subject invention is a condensate treatment and removal system for compressors, particularly portable compressor units.

[0007] The condensate is separated from the airflow through a moisture separator. The separated condensate is then directed to a heat transfer device (e.g., shell and tube, bar and plate, etc.). Once through the heat transfer device, the condensate is sprayed onto an electric heating element in an evaporative heater. Finally, the evaporated condensate is dumped into the compressor cooling fan airflow.

[0008] Aspects of the present disclosure include a condensate treatment system including a separator for separating condensate from an airflow exiting the compressor, a heat exchanger for heating the separated condensate, an evaporative heater for evaporating the heated condensate exiting the heat exchanger, and a vent tube through which the evaporated heated condensate mixes with cooling air exiting the compressor.

[0009] Aspects of the present disclosure further include a combined compression and condensate treatment system including a compressor for compressing an air flow and a condensate treatment system integrated with the compressor in the combined compression and condensate treatment system including a separator for separating condensate from the air flow exiting the compressor, a heat exchanger for heating the separated condensate, an evaporative heater for evaporating the heated condensate exiting the heat exchanger, and a vent tube through which the evaporated heated condensate mixes with cooling air exiting the compressor.

[0010] Aspects of the present disclosure further include a method of treating compressor condensate including separating condensate from an airflow exiting the compressor in a condensate treatment system, heating the separated condensate in a heat exchanger, evaporating the heated condensate exiting the heat exchanger, and mixing the evaporated condensate with cooling air exiting the compressor in a vent tube. The compressor is attached to the condensate treatment system such that the condensate treatment system and the compressor are an integral part.

[0011] Aspects of the present disclosure further include a condensate treatment system including a separation means for separating condensate from the airflow exiting the compression means, a heat exchange means for heating the separated condensate, an evaporative heating means for evaporating the heated condensate exiting the heat exchange means, and aeration means for mixing the evaporated heated condensate with cooling air exiting the compression means.

[0012] Exemplary aspects of the present disclosure can provide a combined and integrated condensate recovery system and compression so that customers no longer need an external condensate recovery system, and can also solve the problem of disposing of the recovered condensate in conventional compressors. [Brief description of the drawings]

[0013] A general architecture for implementing various features of the present disclosure will now be described with reference to the drawings. The drawings and associated description are provided to illustrate example embodiments of the present disclosure and are not intended to limit the scope of the disclosure. Reference numbers are re-used throughout the drawings to indicate correspondence between referenced elements. [Figure 1] 1 illustrates an exemplary condensate recovery system for an air compressor, according to an exemplary embodiment. [Diagram 2] 1 illustrates an exemplary diagram of a condensate recovery system integrated into an air compressor, according to an exemplary embodiment; [Diagram 3] 1 illustrates an exemplary diagram of an evaporative heater of an exemplary condensate recovery system, according to an exemplary embodiment. [Figure 4] 1 illustrates an example of a condensate recovery system, according to an example embodiment. [Diagram 5] 1 illustrates exemplary fluid transfer paths in an exemplary condensate recovery system, according to an exemplary embodiment. [Figure 6] 1 illustrates an example of a method for condensate recovery, according to an example embodiment. [Figure 7] 1 illustrates an example diagram of a control system for an evaporative heater of an example condensate recovery system, according to an example embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] The following detailed description provides further details of the figures and exemplary embodiments of the present application. Reference numbers and descriptions of elements that overlap between figures are omitted for clarity. Terms used throughout the description are provided by way of example and are not intended to be limiting. For example, the use of the term "automatic" may include fully automatic embodiments, or semi-automatic embodiments with user or operator control over certain aspects of the embodiment, depending on the desired implementation of the skilled artisan practicing the embodiments of the present application. Furthermore, sequential terms such as "first", "second", "third", etc. may be used in the specification and claims merely for labeling purposes and should not be limited to indicate that the described operations or items occur in the order described. Operations or items may be arranged in different orders and may be performed in parallel or dynamically without departing from the scope of the present disclosure.

[0015] The exemplary embodiments described herein include a portable compressor package that can provide a solution for managing condensate generated by the compression of moist air.

[0016] After cooling the compressed air, the moisture entrained with the air is condensed to obtain a saturated compressed air / water mixture which is sent through a water separator and a coalescing filter where the condensed water is separated from the compressed air.

[0017] This condensate is then sent to a heat exchanger. The waste heat of compression from the compressor oil is utilized to heat the condensate to a higher temperature before injection into the evaporative heater module. This use of waste heat reduces the power requirements of the evaporative heater and increases the overall efficiency of the system. Different types of heat exchangers (e.g., using shell and tube, brazed plates, etc.) can be used to achieve the pre-heating of the condensate.

[0018] Additionally, the heat contained in the evaporative heater module can be used to preheat the condensate by sending it through a heat transfer tube into the device.

[0019] From the heat exchanger, the condensate is sent to an evaporative heater module. As the condensate is under pressure, an orifice or nozzle is used to atomize the condensate and spray it directly onto an electrically powered heating element. The heat in the evaporative heater and the surface temperature of the element cause the condensate to evaporate.

[0020] The number and size of the heating elements can be modified to accommodate the amount of condensate entering the module. The evaporator heater can be insulated to improve warmth and performance in cold weather. It is also envisioned to utilize a heating plate for evaporation instead of individual elements.

[0021] The evaporated condensate then exits the evaporator heater through vents that are intentionally located in the cooling air stream so that the evaporated condensate mixes with the warm cooling air and is carried out of the machine before it has a chance to condense back into water.

[0022] The evaporator module, heat exchanger, vent tubes and associated piping, and electrical connections are all seamlessly integrated into the compressor package to provide a complete solution. Controls are integrated to power the heater when the compressor is running to produce compressed air.

[0023] Fault protection can be provided to detect when the condensate level is high in the evaporator module or when the heater element has failed. Additionally, bypass piping is provided to allow the condensate to be sent to a collection vessel in the event of a fault.

[0024] FIG. 1 illustrates an example configuration of a condensate recovery system 10 for an air compressor, according to an example embodiment.

[0025] Exemplary components of the condensate recovery system 10 may include, but are not limited to, a separator connected to a separation tube 13, a heat exchanger 12, an evaporative heater 11, and a vent tube 14.

[0026] The saturated compressed air / water mixture resulting from cooling of the compressed air passes through a water separator and coalescing filter where the condensed water is separated from the compressed air and collected in a separation tube 13.

[0027] This condensate is then sent to the heat exchanger 12 through a separation tube 13 .

[0028] In the heat exchanger 12, waste heat of compression from the compressor oil can be added to heat the condensate to a high temperature before it is injected into the evaporative heater 11.

[0029] Furthermore, in the heat exchanger 12, the heat contained in the evaporation heater 11 can be used to preheat the condensate.

[0030] From the heat exchanger 12, the condensed water is sent to the evaporation heater 11. The condensed water is evaporated by the heat in the evaporation heater 11 and the surface temperature of the element of the evaporation heater 11.

[0031] The number and size of the heating elements can be modified to suit the amount of condensate entering the evaporative heater 11 .

[0032] The evaporated condensate then exits the evaporative heater 11 through vent tube 14. Vent tube 14 provides a place for the evaporated condensate to mix with the warm cooling air exiting the compressor before it has a chance to condense back into water.

[0033] The evaporative heater 11, heat exchanger 12, vent tube 14, separator tube 13, associated piping, and electrical connections are all seamlessly integrated into the compressor package to provide a compact compressor and condensate handling system.

[0034] FIG. 2 illustrates an exemplary diagram of a hybrid condensate recovery system incorporated into an air compressor 20, according to an exemplary embodiment.

[0035] As shown in exemplary FIG. 2, the components of the condensate recovery system 10 shown in FIG. 1 and described above are mounted to a compressor 24 to provide a compact condensate treatment system integrated with the compressor 24.

[0036] The evaporated condensate flowing out of the evaporative heater 11 is conveyed to the conduit 21 of the compressor 24 so as to be introduced into the outlet duct 23 of the compressor 24 for mixing with the cooling airflow having passed through the fan 22 of the compressor 24.

[0037] The vent arrangement is intentionally located in the cooling air flow through conduit 21 and outlet duct 23 so that evaporated condensate mixes with the cooling air passing through fan 22 and is conveyed out of the combined condensate recovery system and air compressor 20 before it has a chance to condense back into water.

[0038] FIG. 2 shows the separator components connected to the separation tube 13 , which components include a filter 16 and a water separator 15 .

[0039] The filter 16 and water separator 15 act as a collector separator to separate condensed water from the compressed air in the compressor 24 for heating in the heat exchanger 12, evaporation in the evaporative heater 11, delivery to the conduit 21 and mixing with the cooling air stream in the outlet duct 23.

[0040] FIG. 3 illustrates an exemplary diagram of an evaporative heater 11 of an exemplary condensate recovery system, according to an exemplary embodiment.

[0041] The evaporation heater 11 may be built into, for example, a stainless steel welded box and hardware 33 .

[0042] As the condensate is under pressure within the evaporative heater 11, an orifice or nozzle 35 is used to atomize the condensate and spray it directly onto the electrically powered heating element 31. The heat within the evaporative heater 11 and the surface temperature of the heating element 31 cause the condensate to evaporate.

[0043] The number and size of the heating elements 31 can be modified to accommodate the amount of condensed water that enters the evaporative heater 11 and exits through the vents 32 after evaporation.

[0044] The evaporative heater 11 may be insulated, for example with a gasket cover 34, to improve warmth and performance in cold weather.

[0045] An exemplary embodiment may include a heating plate for evaporation instead of individual heating elements 31 .

[0046] FIG. 4 illustrates an example of a condensate recovery system, according to an example embodiment.

[0047] In the exemplary condensate recovery system of FIG. 4, a shell-and-tube heat exchanger 41 preheats the condensate flowing into the heat exchanger 41 from the separation tube 13 and transfers the preheated condensate to the evaporation heater 11.

[0048] FIG. 5 illustrates exemplary fluid transfer paths in an exemplary condensate recovery system, according to an exemplary embodiment.

[0049] As previously mentioned, the condensate path includes the filter outlet liquid and moisture exhaust to the heat exchanger O / C before entering the condensate nozzles in the evaporator heater where the condensate evaporates for an outlet to the evaporation vent.

[0050] A bypass valve, a bypass drain valve, and an evaporative drain are provided in the condensate path to allow the condensate to be sent to a collection vessel in the event of a failure of the condensate handling system.

[0051] The heat transfer medium is fed to the heat exchange O / C through the cooler tubes to preheat the condensate before it enters the condensate nozzles.

[0052] Based on the exemplary condensate treatment system shown in Figures 1-5 and described above, an exemplary embodiment of the present disclosure is directed to a condensate treatment system 10 including a separator 15 / 16 that separates condensate from the air flow exiting the compressor 24, a heat exchanger 12 that heats the separated condensate, an evaporative heater 11 that evaporates the heated condensate exiting the heat exchanger 12, and a vent tube 14 through which the evaporated heated condensate mixes with the cooling air exiting the compressor 24.

[0053] The condensation water is present in the compressed moist air in the airflow from the cooling fan 22 .

[0054] The separator includes a water separator 15 and a number of filters 16. The heat exchanger 12 adds heat of compression from the compressor oil of the compressor 24 to heat the condensate.

[0055] In an exemplary embodiment, the heat exchanger 12 includes a shell-and-tube heater. In another exemplary embodiment, the heat exchanger 12 includes a brazed plate.

[0056] The evaporative heater 11 includes an orifice or nozzle 35 that atomizes the heated condensate and sprays it onto the heating element 31. The heat contained within the evaporative heater 11 preheats the heated condensate.

[0057] The condensate treatment system 10 is integrated with a compressor 24 in a portable compression and condensate treatment system 20 .

[0058] The condensate treatment system 10 is attached to the compressor 24 such that the condensate treatment system and the compressor are an integral unit.

[0059] The entire condensate treatment system 10 and compressor 24 are a single, portable, integrated unit.

[0060] Another exemplary aspect of the present disclosure is directed to a combined compression and condensate treatment system 20 including a compressor 24 for compressing an air flow and a condensate treatment system 10 integrated with the compressor 24 within the combined compression and condensate treatment system 20.

[0061] The condensate treatment system 10 includes a separator 15 / 16 that separates condensate from the airflow exiting the compressor 24, a heat exchanger 12 that heats the separated condensate, an evaporative heater 11 that evaporates the heated condensate exiting the heat exchanger 12, and a vent tube 14 in which the evaporated heated condensate mixes with the cooling air exiting the compressor 24.

[0062] The condensate treatment system 10 is attached to the compressor 24 such that the condensate treatment system 10 and the compressor 24 are an integral unit.

[0063] The entire condensate treatment system 10 and compressor 24 are a single, portable, integrated unit.

[0064] Another exemplary aspect of the present disclosure is directed to a condensate treatment system 10 including a separation means 15 / 16 for separating condensate from the air flow exiting the compression means 24, a heat exchange means 12 for heating the separated condensate, an evaporation heating means 11 for evaporating the heated condensate exiting the heat exchange means 12, and an aeration means 14 for mixing the evaporated heated condensate with the cooled air exiting the compression means 24.

[0065] Another exemplary embodiment of the present disclosure is directed to a method 60 for treating condensate of compressor 24, as shown, for example, in FIG.

[0066] The method 60 includes separating condensate from the airflow exiting the compressor 24 in the condensate treatment system 10 in step 61, heating the separated condensate in the heat exchanger 12 in step 62, evaporating the heated condensate exiting the heat exchanger 12 in step 63, and mixing the evaporated condensate with cooling air exiting the compressor 24 in the vent tube 14 in step 64.

[0067] The compressor 24 is mounted to the condensate treatment system 10 such that the condensate treatment system 10 and the compressor 24 are an integral whole.

[0068] Another exemplary aspect of the present disclosure is shown in FIG. 7 illustrating an exemplary diagram of a control system for an evaporative heater 11 of an exemplary condensate recovery system, according to an exemplary embodiment.

[0069] The evaporation heater 11 is connected to an inlet condensate pipe 71 , a vent pipe 14 , and an outlet pipe 72 .

[0070] In the exemplary evaporative heater 11 of FIG. 7, a single heating element 74 provides evaporative heating, which may result in better maintainability and design simplicity compared to multiple heating elements in the evaporative heater 11.

[0071] The control scheme for operation of the evaporative heater 11 includes a temperature probe 73 to control the temperature of the heating element 74, a condensate level limit switch 75 to control the level of condensate in the evaporative heater 11, a heating element on switch 76, a heating element test switch 77 for testing and calibrating the heating element 74, and a heating element off switch 78 for overall control of the evaporative heater 11.

[0072] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description of the specific embodiments herein is not intended to limit the invention to the particular forms disclosed.

[0073] In the preceding detailed description, various exemplary embodiments of the apparatus and / or process are described using figures, schematics, and examples. To the extent that such figures, schematics, and examples include one or more functions and / or operations, each function and / or operation in such figures or examples may be individually and / or collectively performed by a wide range of structures. Although specific exemplary embodiments have been described, these embodiments are presented merely as examples and are not intended to limit the scope of protection. Indeed, the novel methods and apparatus described herein may be embodied in various other forms. Furthermore, various omissions, substitutions, and changes may be made in the form of the apparatus and systems described herein without departing from the spirit of protection. The appended claims and their equivalents are intended to cover such forms or modifications that fall within the scope and spirit of protection.

Claims

1. a separator for separating condensate from the airflow exiting the compressor; a heat exchanger for heating the separated condensed water; an evaporation heater for evaporating the heated condensed water flowing out from the heat exchanger; a vent tube through which the evaporated heated condensate mixes with the cooling airflow exiting the compressor; A condensate treatment system.

2. The condensate treatment system of claim 1 , wherein the condensate is in compressed moist air in the air stream.

3. The condensate treatment system of claim 1 , wherein the separator comprises a water separator and a plurality of filters.

4. The condensate treatment system according to claim 1 , wherein the heat exchanger adds heat of compression from compressor oil of the compressor to heat the condensate.

5. The condensate treatment system of claim 1 , wherein the heat exchanger comprises a shell-and-tube heater.

6. The condensate treatment system of claim 1 , wherein the heat exchanger comprises a brazed plate.

7. The condensate treatment system of claim 1 , wherein the evaporative heater includes an orifice or nozzle that atomizes the heated condensate and sprays it onto a plurality of heating elements.

8. The condensate treatment system of claim 1 , wherein the heated condensate is preheated by heat contained in the evaporative heater.

9. The condensate treatment system of claim 1 , wherein the condensate treatment system is integrated with the compressor in a portable compression and condensate treatment system.

10. The condensate treatment system of claim 1 , wherein the condensate treatment system is attached to the compressor such that the condensate treatment system and the compressor are an integral unit.

11. 10. The condensate treatment system of claim 1, wherein the entire condensate treatment system and compressor are a single, portable, integrated unit.

12. 2. The condensate treatment system of claim 1, wherein the evaporative heater includes a single heating element, the evaporative heater including one of an orifice and a nozzle that atomizes and sprays the heated condensate onto the single heating element.

13. The evaporation heater is a temperature probe for controlling the temperature of the single heating element; a plurality of switches for controlling operation of the single heating element within the evaporation heater; The condensate treatment system of claim 12 further comprising:

14. The plurality of switches include a condensate level limit control switch; A heating element on switch; Heating element off switch and The condensate treatment system of claim 13 , comprising:

15. 1. A combined compression and condensate treatment system comprising: a compressor for compressing the air flow; a condensate treatment system integrated with said compressor in said combined compression and condensate treatment system; Including, The condensate treatment system comprises: a separator for separating condensed water from the airflow exiting the compressor; an evaporation heater for evaporating the condensed water; a vent tube through which the evaporated heated condensate mixes with the cooling airflow exiting the compressor; A combined compression and condensate treatment system comprising:

16. a heat exchanger for heating the separated condensed water before it flows into the evaporative heater; 16. The combined compression and condensate treatment system of claim 15, further comprising:

17. 16. The combined compression and condensate treatment system of claim 15, wherein the condensate treatment system is attached to the compressor such that the condensate treatment system and the compressor are an integral whole.

18. 16. The combined compression and condensate treatment system of claim 15, wherein the entire condensate treatment system and the compressor are a single, portable, integrated unit.

19. A method for treating condensate water of a compressor, comprising the steps of: separating the condensate from the airflow exiting the compressor in a condensate treatment system; heating the separated condensate in a heat exchanger; evaporating the heated condensate exiting the heat exchanger; mixing the evaporated condensate with cooling air exiting the compressor through a vent tube; Including, the compressor is attached to the condensate treatment system such that the condensate treatment system and the compressor are an integral part; Processing methods.

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