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Fig. 5.5: Condensate precipitation when
compressing with a dryer
| An example shows the amount of condensate q c that actually occurs when air is compressed. It is also noted that the condensate occurs at several points of the compressor station and at different times.
The task here is to calculate the occurrence of condensate on a screw compressor with an output of  = 2720m³/h and a final compression pressure of p op = 10,5 bar. Connected in series to the compressor are a compressed air tank and a refrigeration compressed air dryer.
The atmospheric air contains a certain amount of water under these conditions:
During the compression process, the temperature rises above the pressure dew point of the compressed air, and therefore no moisture will precipitate. In the aftercooler of the compressor the compressed air is cooled down to T 2 = 40° C. The first condensate occurs and is taken with the air into the compressed air receiver. The volume flow calms down and the droplets of water precipitate. A considerable amount of condensate collects there:
After this the compressed air is cooled down in the refrigeration compressed air dryer to a temperature corresponding to a pressure dew point of 3° C. The condensate precipitates in the dryer and is drained off.
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Fig. 5.6: Approx. 8 10 l buckets of condensate precipitate
in 24 hours | In addition to the individual flows of condensate, there is also the quantity of condensate that needs to be dealt with by the condensate treatment equipment.
Condensate quantity qC = qC1 + qC2
Condensate quantity qC = 75441,9 g/h = 75,4 l/h
With 3-shift operation working at 100 % efficiency the compressor is running 24 hrs. per day. This means, with the basic assumptions unchanged:
Condensate quantity qCD = 1810605,6 g/D = 1810,6 l/D
The following quantity of condensate will then occur in one year:
Condensate quantity qCY = 659060438 g/Y = 659060 l/Y
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