Oil/Water Separators. Efficient on-site disposal of compressed air condensate

Transcription

1 TOPRING Oil/Water Separators Series 57 Efficient on-site disposal of compressed air condensate S57 Oil/Water Separators / Version Jan / ON Discharging oil contaminated condensate is not only harmful to environment, it s illegal!

2 Oil and Water in Compressed Air System WATER ACCUMULATION When compressing air, a compressor draws in many other substances including water vapor. The compression process causes this water vapor to condense and accumulate in receivers, tanks and compressed air systems. The most obvious place for this condensate to accumulate is in the compressor tank. In addition to damaging the tank, this condensate will COMPRESSOR OILS In compressors with lubricated compression chambers, the compressed air unavoidably picks up some oil. The most common examples of these types of compressors are oil-flooded rotary screw machines, lubricated reciprocating, and rotary vane compressors. In most cases, manufacturers of these types of compressors report oil carryover in ppm or parts per million by weight. Fact is a reciprocating compressor does have a higher ppm (parts per million) level of oil carryover then a rotary screw, average ppm of a reciprocating compressor 7-10 ppm and it gets worse as it ages and on the rotary screw 3-5 ppm with oil separation that if maintained regularly will keep it in it s range. also be entrained in the air flow and be drawn into the compressed air network. Removing this condensate from the compressed air system is vitally important, as even small quantities can have a significantly detrimental effect on downstream equipment. In the compressor air business, most people have a difficult time relating to 2 ppm. In the real world, many lubricated compressors run at considerably higher oil carryover levels. In fact, many installations frequently run over 25 ppm. At a concentration of 25 ppm, a typical compressor flowing 100 scfm for 35 hours will introduce 240 ml of oil into the pneumatic system. This oil gets into the flow of air and can mix with water vapor, liquid water and other contaminants to form a thick, viscous substance even more damaging to downstream components. For all these reasons, condensate removal is crucial to any compressed air system. Condensate removal using automatic drains is simple and efficient, but for the disposal of contaminant, oil/water s eparator is essential to comply with municipal regulations. A 50 HP compressor will pass about 120 ml of oil in 24 hours at 10 ppm. LITERS of water AFTER 8 hours FOR A 25HP COMPRESSOR (100 SCFM) Ambient Air % Humidity Temperature C 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 % P2

3 Disposal of Contaminated Condensate A typical compressed air system will produce thousands of litres of oily, contaminated condensate every year. For example, a 100 scfm compressor/ refrigeration dryer package, operating in a 25 C, 65% relative humidity for hours can produce up to litres of condensate. Oil can seriously affect the efficient operation of sewage purification. For this reason, very little oil is permitted in water discharge and rigid legislation exists in most municipalities to protect the environment against this type of contamination. International standards such as ISO also require the compressed air user to comply with local environmental legislation and show use of protective systems and procedures. Traditional solutions for condensate disposal have been to: Collect the condensate and have it trucked away periodically by a waste disposal company. This not only requires storage of the hazardous condensate on site, posing a health and safety risk, it is very costly as disposal charges can be up to several dollars per gallon. Use a settling tank to separate the oil and water by gravity, then using carbon to filter the remaining water. Advances in compressor lubricants have made this technology obsolete. Modern compressor lubricants have a specific gravity similar to water, and because of this, they form an emulsified oil/water mixture that cannot be separated by gravity. Efficient on-site Disposal of Condensate TOPRING offers a new line of condensate separators that works anywhere, anytime, on virtually any condensate, and with any type of condensate drain. TOPRING oil/water separators are a simple, economical and environmental solution. These oil/water separator are installed as part of the compressed air system and reduce the oil concentration in the collected condensate with a larger volume of clean water, up to 99.9% with a relatively small amount of concentrated oil that can be discharged legitimately and economically. Using a specially treated, adsorbent, polypropylene media, TOPRING oil/water separators efficiently and effectively separate all compressor lubricants without the need for condensate storage tanks, settling chambers, or costly disposal. TOPRING oil/water separators are the most cost effective and reliable solution to meet environmental regulations for condensate treatment, and ensure your compliance with ISO Specialized polypropylene media Activated carbon polishing filter No need for a settling chamber Cost effective, reliable performance Works on virtually any condensate Works with any condensate drain DISPOSAL OF COMPRESSED AIR CONDENSATE COMPRESSOR RECEIVER TANK AUTO DRAIN REFRIGERATED DRYER OIL/WATER SEPARATOR 10 mg/l = 10 ppm/volume CONDENSATE DRAIN LINE ± 10 mg/l of oil residue values at the output stage! P3

4 70 scfm UP TO Disposable Condensate Separator Simple and cost effective way to meet environmental regulations for condensate disposal. With an advanced polypropylene adsorbent media, it can separate virtually any condensate containing any compressor lubricant discharged from any type of condensate drain, and it does so without the need for a condensate settling tank or storage chamber. Simply mount it to the wall, connect the inlet and outlet for clean condensate. When it s full of oil - just replace it. FEATURES AND BENEFITS Foam depressurization layer: separates condensate and compressed air Polypropylene media: adsorbs compressor oil Carbon polishing media: filters out any remaining hydrocarbons Simple replaceable design: just remove and replace it when it s full Rugged ABS housing: lightweight, yet strong and durable No settling chamber: perfect for portable applications Brass inlet and outlet adapter: for secure or tubing connections Wall mounting kit included: easy to install. No floor space required APPLICATIONS Perfect for installations with : Low compressed air flows (up to 70 scfm) Low condensate flows Portable applications or floor space restrictions Any type of compressor oil Emulsified mixtures Any type of condensate drain EPA discharge regulations Operating cost concerns MATERIAL ABS 25.5 cm 25 cm 21 cm 23 cm The oil adsorbing elements combine various types of adsorption technologies to achieve less than 10 mg/l of oil residue values at the output stage. Quick and easy to service Fixing brackets included Brass inlet/outlet connection Test kit included Mineral and synthetic lubricants applications Polyglycol applications Max flow capacity scfm Max oil adsorption litres I.D. Inlet/Outlet Weight kg /2 3.6 P4 Rule of thumb: 1 HP = 4 scfm

5 125 scfm UP TO Condensate Separator With an advanced polypropylene adsorbent media and a carbon polisher, it can separate virtually any condensate containing any compressor lubricant discharged from any type of condensate drain, and it does so without the need for a condensate settling chamber or storage tank. A cost effective and reliable solution to meet environmental regulations for condensate disposal. FEATURES AND BENEFITS No settling chamber or storage tank required: eliminates health and safety concerns Can separate any type of lubricant: including modern synthetic lubricants or even emulsified mixtures Can be used with any type of drain: including all TOPRING condensate drains Brass threaded inserts & adapters: for secure threaded or tubing connections Foam mesh depressurization chamber with foam exhaust filter: slows incoming condensate and cleanly discharges compressed air Three stage of treatment: two polypropylene elements and carbon polisher for optimum performance Multiple lightweight media bag: comply with OSHA lifting requirements Rugged polyethylene housing: strong and corrosion proof construction Wall mounting kit optional: easy to install. No floor space required APPLICATIONS Perfect for installations with: Portable applications Any type of compressor oil Emulsified mixtures Any type of condensate drain Floor space restrictions EPA discharge regulations Operating cost concerns 21 cm 38.5 cm 39.5 cm Mineral and synthetic lubricants applications Polyglycol applications Max flow capacity scfm The oil adsorbing elements combine various types of adsorption technologies to achieve less than 10 mg/l of oil residue values at the output stage. Max oil adsorption litres I.D. Inlet/Outlet Weight kg /2 8.2 MATERIAL Polyethylene Depressurization chamber Test port & kit included ELEMENT SERVICE kit: PLAN ahead! For separator Service kit for Service kit for Complete unit When it is time to replace the elements, it is important to have in hand a service kit to replace all 3 elements. Service kit includes: 2 polypropylene elements and 1 carbon polisher. P5

6 1250 SCFM UP TO HIFLO Condensate Separators TOPRING Oil water separators 175 scfm through 1250 scfm use three stages of treatment to separate difficult condensate. With two specially treated polypropylene elements and a carbon polisher, you can count on reliable and cost effective condensate separation performance regardless of the type of lubricant or drains you use. These models are loaded with useful features, like a visual element life indicator that lets you know when your elements need to be replaced, and an overflow indicator to avoid messy spills. Each separator includes 4 the primary, secondary and carbon polisher media bags 4 a sample bottle and sample port for water quality testing to ensure compliance with local environmental regulations 4 a step by step instruction manual for installation and operation Element life indicator One unique feature of the HIFLO separators is the element life indicator. This indicator gives instant visual confirmation of the condition of the elements in the separator and when they need to be replaced. When the primary indicator element is new, it floats on top of the condensate in the first tower. As condensate enters the separator over time, the oil becomes trapped within the fibers of the polypropylene media. This additional weight will cause the element to sink. As it sinks the element life indicator begins to lower. When the element is fully saturated with oil, the indicator will be all the way down. This indicates that it is time to replace all three. Indicator is up Element is clean Indicator at half Element is halfull Indicator down Replace element The oil adsorbing elements combine various types of adsorption technologies to achieve less than 10 mg/l of oil residue values at the output stage. P6

7 FEATURES AND BENEFITS No settling chamber or storage tank required: eliminates health & safety concerns. Performance is not affected by movement Can separate any type of lubricant: Including modern synthetic lubricants or even emulsified mixtures Can be used with any type of drain: including all TOPRING condensate drains Brass threaded inserts & adapters: for secure threaded or tubing connections Foam mesh depressurization chamber with foam exhaust filter: slows incoming condensate and cleanly discharges compressed air Visual element life indicator: provides confident indication of element conditions. Overflow warning indicator: Avoids spill in the event of a blockage Three stage of treatment: two polypropylene elements and carbon polisher for optimum performance Multiple lightweight media bag: comply with OSHA lifting requirements Rugged polyethylene housing: strong and corrosion proof construction APPLICATIONS Perfect for installations with: High compressed air flows Any type of compressor oil High condensate flows Emulsified mixtures Any type of condensate drain Portable applications Floor space restrictions Operating cost concerns MATERIAL Polyethylene EPA discharge regulations Accessories Condensate test kit Useful tool to demonstrate the oil adsorbing capabilities of the media and prove it s effectiveness on the condensate at a given application prior to installation. The test can be carried out on site, and the kit includes a detailed step-by-step instruction manual to walk through the simple test procedure. Description Condensate test kit Brass multiple inlet adaptator Increases inlet connections from two to four Description Inlet adaptor Mineral and synthetic lubricants applications Polyglycol applications Max flow capacity SCFM Max oil adsorption litres Dimensions W x H x D cm I.D. Inlet/Outlet Weight kg / x 61 x / x 75 x / x 90 x / x 90 x 38 ELEMENT SERVICE kit: PLAN ahead! When the indicator is all the way down, it is time to replace all three elements. It is important to always have a service kit to replace all 3 elements (2x polypropylene and 1x carbon media). Indicator down Replace element For Separator Service kit for Service kit for Service kit for Service kit for Service kit for Service kit for Service kit for Service kit for Rule of thumb: 1 HP = 4 scfm P7

8 Ontario Environmental Protection Act Prohibition, contamination generally 6.(1) No person shall discharge in the natural environment any contaminant, and no person responsible for a source of contaminant shall permit the discharge into the natural environment of any contaminant from the source of contaminant, in an amount, concentration or level in excess of that prescribed by the regulations. E.P.A. R.S.O. 1990, c E.19, a 6.(1) TOPRING Source: Distributed by TOPRING.com