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What are the different types of water separators used in air compressors, and how do they work?

2022-06-21View Original

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The moisture content in compressed air is relatively high; it is necessary to pre-treat the moisture in the gas by using a steam-water separator to separate most of the liquid from the gas, thereby obtaining drier compressed gas. How to use a steam-water separator? A steam-water separator is a pressure vessel made of carbon steel or stainless steel, with flange-type connections in DN16/DN25/DN40 sizes ; The steam-water separator must be installed on a horizontal pipeline, with the drain outlet pointing vertically downward. All sizes of steam-water separators come with mounting brackets to reduce the load on the pipeline. To ensure the rapid discharge of the separated liquid, a suitable set of steam traps should be connected to the drain outlet at the bottom of the gas-liquid separator. Valves of this type should generally be installed horizontally in pipelines. Although there are various designs of separators, their purpose is to remove the moisture suspended in the steam that cannot be expelled through the steam trap. There are three types of separators commonly used in steam systems. Baffle type – Baffle or flap-type separators are composed of numerous baffles; the fluid changes direction multiple times as it flows through the separator. Due to the large mass and inertia of the suspended water droplets, when the flow direction changes due to the baffles, the dry steam can bypass these baffles and continue moving forward, while the water droplets accumulate on the baffles. Steam-water separators have a large flow area, which reduces the kinetic energy of the water droplets; most of them coagulate and eventually fall to the bottom of the separator, where they are discharged through a drain valve. Cyclone type – Cyclone or centrifugal separators utilize a series of ribs to generate a high-speed cyclone, causing the steam to flow at high speed while rotating within the separator. Adsorption type – There is an obstacle in the steam channel inside the adsorption-type separator; it is usually a metal mesh pad. The suspended water droplets are absorbed when they come into contact with this pad, and once they grow large enough, they fall to the bottom of the separator due to gravity. Separators that combine cyclone and adsorption methods are also common, as the use of both approaches improves the overall separation efficiency. The main difference among baffle-type, cyclone-type, and adsorption-type separators is that the baffle-type separator can maintain a high separation efficiency over a wide range of flow velocities, while the separation efficiency of cyclone-type and adsorption-type separators can only reach 98% when the steam velocity is below 13 m/s; otherwise, the efficiency is very low. At a steam velocity of 25 m/s, their separation efficiency is approximately only 50%. Studies show that the separation efficiency of baffle separators can approach 100% within a flow velocity range of 10 m/s to 30 m/s; therefore, they are more suitable for use in steam systems when there are significant velocity fluctuations. Moreover, if the pipes are sized too small, the velocity of the wet steam can exceed 30 m/s. One way to solve this problem is to increase the diameter of the steam-water separator as well as that of the pipes upstream of the separator, in order to reduce the steam flow rate entering the steam-water separator.

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