U.S. patent application number 14/860037 was filed with the patent office on 2017-03-23 for condensate vaporization system.
The applicant listed for this patent is CLARK EQUIPMENT COMPANY. Invention is credited to John Thomas Gunn, Richard Louis Kouzel.
Application Number | 20170082098 14/860037 |
Document ID | / |
Family ID | 57189735 |
Filed Date | 2017-03-23 |
United States Patent
Application |
20170082098 |
Kind Code |
A1 |
Gunn; John Thomas ; et
al. |
March 23, 2017 |
CONDENSATE VAPORIZATION SYSTEM
Abstract
An air compressor system includes a compressor having an intake
end and a discharge end, the compressor operable to draw in
atmospheric air at the intake end and to discharge a flow of
compressed air from the discharge end, the flow of compressed air
including a flow of entrained water vapor and lubricant. The system
further includes a separator operable to remove a portion of the
entrained water vapor and lubricant from the flow of compressed
air, the separator discharging a flow of dry compressed air and a
flow of effluent which includes the separated water vapor and
lubricant. Further, the system includes an electric heater
configured to receive the removed effluent from the separator at an
entrance to the electric heater and to vaporize the removed
effluent.
Inventors: |
Gunn; John Thomas;
(Charlotte, NC) ; Kouzel; Richard Louis;
(Mooresville, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CLARK EQUIPMENT COMPANY |
Statesville |
NC |
US |
|
|
Family ID: |
57189735 |
Appl. No.: |
14/860037 |
Filed: |
September 21, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 39/16 20130101;
F04C 29/02 20130101; F04C 29/026 20130101 |
International
Class: |
F04B 39/16 20060101
F04B039/16 |
Claims
1. An air compressor system comprising: a compressor having an
intake end and a discharge end, the compressor operable to draw in
atmospheric air at the intake end and to discharge a flow of
compressed air from the discharge end, the flow of compressed air
including a flow of entrained water vapor and lubricant; a
separator operable to remove a portion of the entrained water vapor
and lubricant from the flow of compressed air, the separator
discharging a flow of dry compressed air and a flow of effluent
which includes the separated water vapor and lubricant; and an
electric heater configured to receive the removed effluent from the
separator at an entrance to the electric heater and to vaporize the
removed effluent.
2. The air compressor system of claim 1, wherein the system
includes an aftercooler coupled to the discharge end of the
compressor and an intake end of the separator, the aftercooler
operable to cool the compressed air stream and effluent to condense
a portion of the effluent.
3. The air compressor system of claim 2, wherein the separator
includes a moisture separator configured to remove a portion of the
effluent from the compressed air flow and direct the portion of
effluent to an entrance of the electric heater.
4. The air compressor system of claim 3, wherein the separator
includes at least one filter configured to remove a second portion
of effluent from the compressed air flow and direct the second
portion of effluent to the entrance of the electric heater
5. The air compressor system of claim 1, wherein the electric
heater directs vaporized effluent to atmosphere through an exit of
the electric heater.
6. The air compressor system of claim 1, wherein the system
includes a controller coupled to the compressor and operable to
control the amount of electricity provided to the electric
heater.
7. The air compressor system of claim 6, wherein the system
includes a temperature sensor coupled to the electric heater and
configured to send a temperature measurement to the controller.
8. The air compressor system of claim 7, wherein the controller is
configured to receive the temperature measurement and control the
amount of electricity provided to the electric heater based at
least in part on the temperature measurement.
9. The air compressor system of claim 6, wherein the system
includes a pressure sensor coupled to the compressor and configured
to send a pressure measurement to the controller.
10. The air compressor system of claim 9, wherein the controller is
configured to receive the pressure measurement and control the
amount of electricity provided to the electric heater based at
least in part on the pressure measurement.
11. The air compressor system of claim 6, wherein the system
includes a compressor temperature sensor coupled to the compressor
and configured to send a compressor temperature measurement to the
controller.
12. The air compressor system of claim 11, wherein the controller
is configured to receive the compressor temperature measurement and
control the amount of electricity provided to the electric heater
based at least in part on the compressor temperature
measurement.
13. The air compressor system of claim 6, wherein the system
includes at least one of an ambient air temperature sensor and an
ambient air relative humidity sensor, wherein the ambient air
temperature sensor is configured to send an ambient temperature
measurement to the controller, wherein the ambient relative
humidity sensor is configured to send an ambient humidity
measurement to the controller, and wherein the controller is
configured to receive at least one of the ambient temperature
measurement and the ambient humidity measurement and to control the
amount of electricity provided to the electric heater based at
least in part on at least one of the ambient temperature
measurement and the ambient humidity measurement.
14. An air compressor system comprising: an oil-flooded compressor
having an intake end for the intake of air and a discharge end from
which a compressed air stream with entrained effluent exits the
compressor; an electric motor coupled to the compressor and
operable to drive the compressor; an after cooler coupled to the
discharge end of the compressor and operable to cool the compressed
air stream and effluent to condense a portion of the effluent; a
moisture separator coupled to a discharge end of the after cooler
and configured to remove a portion of the condensed entrained
effluent from the compressed air stream; and an electric
pass-through heater configured to receive the removed effluent from
the moisture separator, and configured to vaporize the removed
effluent.
15. The air compressor system of claim 14, wherein the electric
pass-through heater directs vaporized effluent to the atmosphere
through an exit of the pass-through electric heater.
16. The air compressor system of claim 14, wherein the system
includes a controller coupled to the compressor and operable to
control the amount of electricity provided to the electric
heater.
17. The air compressor system of claim 16, wherein the system
includes a temperature sensor coupled to the electric pass-through
heater and configured to send a temperature measurement to the
controller, and wherein the controller is configured to receive the
temperature measurement and control the amount of electricity
provided to the electric pass-through heater based at least in part
on the temperature measurement.
18. The air compressor system of claim 16, wherein the system
includes at least one of an ambient air temperature sensor and an
ambient air relative humidity sensor, wherein the ambient air
temperature sensor is configured to send an ambient temperature
measurement to the controller, wherein the ambient relative
humidity sensor is configured to send an ambient humidity
measurement to the controller, and wherein the controller is
configured to receive at least one of the ambient temperature
measurement and the ambient humidity measurement and to control the
amount of electricity provided to the electric heater based at
least in part on the at least one of the ambient temperature
measurement and the ambient humidity measurement.
19. A method of operating an electrically-powered air compressor,
the method comprising: powering an oil-flooded compressor to
produce a flow of compressed air and effluent, the effluent
including compressed water vapor and oil; cooling the flow of
compressed air and effluent to condense a portion of the effluent;
separating the flow of compressed air and effluent into a flow of
dry compressed air and a flow of condensed effluent; heating the
flow of condensed effluent in an electrically-powered heater to
vaporize the effluent; and discharging the vaporized effluent to
the atmosphere.
20. The method of claim 19, further comprising measuring a
temperature of the electrically-powered heater and varying the
power provided to the electrically-powered heater at least
partially in response to the measured temperature.
21. The method of claim 19, wherein the powering step includes
powering the compressor with an electric motor.
Description
BACKGROUND
[0001] The present invention relates to a system for vaporizing
effluent discharged from a compressor.
[0002] Compressors are used to compress gas for use in various
processes. Some compressors use oil as a lubricant and a coolant
during compressor operation. The oil lubricates and seals the
compressor and carries away excess heat during use. A small portion
of the oil is typically discharged with the flow of compressed gas
that is discharged from the compressor. In compressor systems that
compress air, the air is typically drawn from the atmosphere and
therefore contains at least some water vapor. During the
compression process, some of this water vapor can condense out of
the compressed air and be carried out of the air compressor with
the small quantity of oil, especially in applications where the
compressed service air is cooled prior to discharge.
SUMMARY
[0003] In one construction of an air compressor system, the system
includes a compressor having an intake end and a discharge end, the
compressor operable to draw in atmospheric air at the intake end
and to discharge a flow of compressed air from the discharge end,
the flow of compressed air including a flow of entrained water
vapor and lubricant. Additionally, the system includes a separator
operable to remove a portion of the entrained water vapor and
lubricant from the flow of compressed air, with the separator
discharging a flow of dry compressed air and a flow of effluent
which includes the separated water vapor and lubricant. Further,
the system includes an electric heater configured to receive the
removed effluent from the separator at an entrance to the electric
heater and to vaporize the removed effluent.
[0004] In another construction of an air compressor system, the
system includes an oil-flooded compressor having an intake end for
the intake of air and a discharge end from which a compressed air
stream with entrained effluent exits the compressor. Additionally,
the system includes an electric motor coupled to the compressor and
operable to drive the compressor. Further, the system includes an
after cooler coupled to the discharge end of the compressor and
operable to cool the compressed air stream and effluent to condense
a portion of the effluent and a moisture separator coupled to a
discharge end of the after cooler and configured to remove a
portion of the condensed entrained effluent from the compressed air
stream. Even further, the system includes an electric pass-through
heater configured to receive the removed effluent from the moisture
separator, and configured to vaporize the removed effluent.
[0005] Another construction provides a method of operating an
electrically-powered air compressor. The method includes powering
an oil-flooded compressor with an electric motor, the compressor
producing a flow of compressed air and effluent, the effluent
including compressed water vapor and oil, cooling the flow of
compressed air and effluent to condense a portion of the effluent,
and separating the flow of compressed air and effluent into a flow
of dry compressed air and a flow of condensed effluent. The method
further includes heating the flow of condensed effluent in an
electrically-powered heater to vaporize the effluent and
discharging the vaporized effluent to the atmosphere.
[0006] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic illustration of a condensate
vaporization system.
[0008] FIG. 2 is a flow chart illustrating a method of operating
the condensate vaporization system of FIG. 1.
[0009] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations herein are meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items.
DETAILED DESCRIPTION
[0010] FIG. 1 schematically illustrates a compressor system 5,
including a condensate vaporization system 10 and a particulate
removal system 15, for producing a compressed gas stream and for
removal of entrained effluent from the compressed gas stream to
produce a stream of clean compressed gas that contains minimal
moisture and lubricant. Effluent is generally defined as a mixture
of water and oil (i.e., primarily water with a small amount of
entrained lubricant), and is essentially the liquid medium that
resides downstream of an aftercooler in a compressor system. Before
proceeding further, it should be noted that the present system can
be used to compress many different gases. However, for clarity, the
system will be described herein as it applies to an air compressor
system. The compressor system 5 includes a compressor 14, a motor
18, an aftercooler heat exchanger 22, a controller 50, a compressor
temperature sensor 58, a compressor pressure sensor 62, an ambient
air temperature sensor 66, and an ambient air relative humidity
sensor 68. The particulate removal system 15 of the compressor
system 5 includes a separator 26 and first and second filters 30,
34. The condensate vaporization system 10 of the compressor system
5 includes an electric heater 38, and a heater temperature sensor
54.
[0011] In the illustrated construction, the compressor 14 is an oil
flooded screw compressor. The compressor 14 includes a compressor
air inlet 70 open to the atmosphere. The compressor 14 further
includes a compressor discharge end 78. The motor 18 couples to the
compressor 14 and is operable to drive the compressor 14. In the
illustrated construction, the motor 18 is an electric motor that
electrically couples to a power source (not shown). In other
constructions the motor 18 can be another prime mover operable to
drive the compressor 14.
[0012] The aftercooler 22 includes an aftercooler inlet 82 that
receives a flow of compressed air from the compressor 14 and an
aftercooler outlet 86 where the cooled compressed air is
discharged. Additionally, the aftercooler 22 fluidly couples to a
cooling source with a cooling fluid (e.g., air, coolant, water)
that passes through the aftercooler 22 such that the cooling fluid
thermally communicates with compressed air that is within the
aftercooler 22 between the aftercooler inlet 82 and the aftercooler
outlet 86.
[0013] The aftercooler 22 discharges the cooled flow of compressed
air to the separator 26 (e.g., a moisture separator or water
separator). The separator 26 includes a separator inlet 90, a first
separator outlet 94, and a second separator outlet 98. The second
separator outlet 98 couples to a discharge line 110.
[0014] Downstream of the aftercooler 22 are the first and second
filters 30, 34. In the illustrated construction, the first and
second filters 30, 34 are coalescing filters. In other
constructions, other types of filters can be used to remove excess
liquid from the compressed air. Further, in some constructions more
than two filters, or fewer filters can be utilized, or no filters
may be utilized.
[0015] Each filter 30, 34 has a filter inlet, an air outlet, and a
condensed effluent outlet. The air outlet of the first filter 30
fluidly couples to the second filter 34. The air outlet of the
second filter 34 is connected to other downstream components that
ultimately lead to a point of use. For example, a storage tank or
large manifold could be connected to the filter 34 to hold a
quantity of compressed air for use as may be required. The
condensed effluent outlets of the first and second filters 30, 34
couple to the discharge line 110.
[0016] The discharge line 110 includes an orifice 114 which is
arranged such that all condensed effluent flowing through the
discharge line 110 passes through the orifice 114. The discharge
line 110 fluidly couples the separator 26 and the first and second
filters 30, 34 to the electric heater 38. The electric heater 38
(e.g., an electric pass-through heater or tankless water heater)
includes a heater inlet 126 and a heater outlet 130. Further, the
electric heater 38 electrically couples to the power source (not
shown). In the illustrated construction, the heater outlet 130 is
open to the atmosphere.
[0017] The controller 50 is preferably a microprocessor-based
controller that electrically couples to the compressor 14 and the
electric heater 38 to control various operational parameters of
both the compressor 14 and the electric heater 38. Further, the
controller 50 electrically couples to the compressor temperature
sensor 58, the compressor pressure sensor 62, the ambient air
temperature sensor 66, the ambient air relative humidity sensor 68,
and the heater temperature sensor 54.
[0018] The compressor temperature sensor 58 and compressor pressure
sensor 62 couple to the compressor 14. For example, the sensors 58,
62 may be disposed in a compressor discharge line or downstream of
the compressor 14 to directly measure the temperature and pressure
of the compressed air exiting the compressor 14. The sensors 58, 62
generate temperature and pressure signals indicative of the
measured temperature and pressure of the compressed air and
transmit the temperature and pressure signals to the controller 50.
The ambient air temperature sensor 66 and the ambient air relative
humidity sensor 68 couple to the compressor 14 near the compressor
air inlet 70. The sensors 66, 68 generate temperature and relative
humidity signals indicative of the measured temperature and
relative humidity of the ambient air entering the compressor 14 and
transmit the temperature and relative humidity signals to the
controller 50. Based on the signals from the sensors 58, 62, 66,
68, the controller is configured to utilize a predictive algorithm
to "ready" (e.g., preheat or otherwise adjust the temperature
and/or energy flow in anticipation of a change in conditions) the
electric heater 38 and prepare the electric heater 38 to vaporize
effluent. The heater temperature sensor 54 couples to the electric
heater 38. For example, the heater temperature sensor 54 may be
disposed inside a discharge line of the electric heater 38 to
directly measure the temperature of the vaporized effluent exiting
the electric heater 38. The heater temperature sensor 54 generates
a temperature signal indicative of a measured temperature of the
vaporized effluent and transmits the temperature signal to the
controller 50.
[0019] The signals from the compressor pressure sensor 62, the
compressor temperature sensor 58, the ambient air temperature
sensor 66, the ambient air relative humidity sensor 68, and the
heater temperature sensor 54 are used in determining how the
compressor 14 and/or electric heater 38 are operated. In other
constructions, the operation of additional components can be
determined by the signals from the sensors 54, 58, 62, 66, 68
(e.g., the motor 18 or the power source). Further, in alternative
constructions, additional sensors 54, 58, 62, 66, 68may be utilized
in similar positions as those described above, or in additional
positions in and around the compressor 14 and the electric heater
38. In preferred constructions, the sensors 54, 58, 62, 66, and 68
transmit analog or digital signals to the controller 50.
[0020] The flowchart of FIG. 2 illustrates operation of the
condensate vaporization system 10 starting with block 200. The
power source provides power to the motor 18, which drives the
compressor 14. The compressor 14 intakes air through the compressor
air inlet 70 from the surrounding atmosphere. Further, in the
illustrated embodiment, a pump (not shown) provides oil to the
compressor 14. The compressor 14 compresses the air, and directs
the air outward through the compressor discharge end 78. During the
compression process, oil is used to seal the compressor 14 and to
cool the compressor 14. As air is discharged, a small portion of
oil is entrained with the air. In addition, the compression process
can cause some moisture to condense within the air stream. The
compressed air directed outward from the compressor 14 includes
this water vapor, oil vapor, and oil additive vapors in the form of
an entrained effluent.
[0021] The aftercooler 22 receives the compressed air at the
aftercooler inlet 82 and cools the air (see block 204) by allowing
thermal communication between the compressed air and the cooling
fluid. Cooling the compressed air condenses a first portion of the
entrained effluent. The aftercooler 22 then directs the compressed
air and the first portion of condensed effluent through the
aftercooler outlet 86 to the separator inlet 90.
[0022] The separator 26 separates the first portion of the
condensed effluent from the compressed air and directs the first
portion through the second separator outlet 98 to the discharge
line 110 (see block 208). The separator 26 then directs the
compressed air through the first separator outlet 94 to the first
and second filters 30, 34.
[0023] In the illustrated construction, the first filter 30
separates a second portion of condensed effluent from the
compressed air. The second portion of condensed effluent passes to
the discharge line 110. The compressed air passes to the second
filter 34. The second filter 34 separates a third portion of
condensed effluent from the compressed air. The third portion of
condensed effluent passes to the discharge line 110. The compressed
air exits out of the particulate removal system 15 in the form of
dry compressed air. In preferred constructions, the air is heated
after exiting the filters to assure that the air temperature is
well above the air's dew point temperature. Generally, dry
compressed air has a dew point at least 20 degrees below the
discharge temperature of the air. The first, second, and third
portions of condensed effluent pass through the discharge line 110
and through the orifice 114. The condensed effluent (e.g., the
first, second, and third portions) then pass through the heater
inlet 126 to the electric heater 38. The orifice 114, in some
constructions, is selected specifically to control the amount of
compressed air lost and to allow the condensate to escape at the
rate accumulated. In other embodiments, a check valve or pressure
reducing valve may be used to decrease the pressure of the
condensed effluent. The power source powers the electric heater 38
to heat the condensed effluent in the electric heater 38. The
electric heater 38 heats the condensed effluent to a temperature at
which water, as well as some additional effluent constituents, will
vaporize. A temperature control can also be employed to limit the
temperature and to control vaporizing of the effluent constituents
as desired (see block 212). In other constructions, additional
electric heaters may be included to provide additional heating to
the condensed effluent. Further, the additional heaters may be
arranged with the electric heater 38, downstream of the discharge
line 110, either in series or in parallel. The vaporized effluent
then passes through the heater outlet 130 to the atmosphere (see
block 216).
[0024] Referring again to FIG. 1, the controller 50 controls the
amount of electricity provided to the electric heater 38 by the
power source. The compressor temperature sensor 58 detects the
temperature of the compressor 14 and sends compressor temperature
measurements to the controller 50. The compressor pressure sensor
62 detects the pressure in the compressor 14 and sends compressor
pressure measurements to the controller 50. The ambient air
temperature sensor 66 detects the temperature of the ambient air
entering the compressor 14 and sends the ambient air temperature
measurements to the controller 50. The ambient air relative
humidity sensor 68 detects the relative humidity of the ambient air
entering the compressor 14 and sends the ambient air relative
humidity measurements to the controller 50. The heater temperature
sensor 54 detects the temperature of the electric heater 38 and
sends heater temperature measurements to the controller 50.
[0025] The controller 50 receives the compressor temperature
measurements, the compressor pressure measurements, the ambient air
temperature measurements, the ambient air relative humidity
measurements, and the heater temperature measurements. Based on one
or more of these measurements, the controller 50 determines and
controls the amount of electricity that is provided to the electric
heater 38 to ensure that the condensed effluent within the electric
heater 38 is fully vaporized. Further, based on the signals from
the sensors 58, 62, 66, 68, the controller 50 may utilize a
predictive algorithm to "ready" (e.g., preheat or otherwise adjust
the temperature and/or energy flow in anticipation of a change in
conditions) the electric heater 38 and prepare the electric heater
38 to fully vaporize the condensed effluent for a given demand
(i.e., kilowatt input or heat load). Further, the ambient
temperature and relative humidity measurements allow the controller
50 to determine the total amount of water coming into the system to
better estimate the amount of heat required to fully vaporize the
effluent.
[0026] Various features and advantages of the invention are set
forth in the following claims.
* * * * *