Description:
TECHNICAL FIELD
[001] The embodiments herein generally relate to compressed air systems and more particularly, to a system and a method for removing liquid condensate from compressed air for use in an industrial plant.

BACKGROUND
[002] Generally, the manufacturing industry uses compressed air for various applications. During the process of compressing air, atmospheric air along with water vapor and atmospheric contaminants are drawn into an air compressor. At the end of compression hot compressed air flows into an aftercooler to remove the heat of compression. Compressed air loses the ability to contain large amounts of water and excessive amounts of water vapors convert into liquid form during cooling of the hot compressed air. Additional condensation takes place as the air is further cooled in the piping and air dryers. Compressed air condensate is a mixture of ambient hydrocarbons, compressor lubricant with ambient moisture and particulates. Condensate in compressed air system can cause many problems as follows. Inconsistent supply of dry air will cause production problems. For example, the moisture will wash away the lubrication from air tools, and cause erratic performance, downtime, and maintenance. The presence of water will lead to the formation of rust and scale in the air piping system thereby causing malfunctioning of the equipment. Further, water can back up into the compressed air system thereby resulting in non-functioning of the machinery. Furthermore, the condensate transferred to the end use can lead to irreparable consequences to the final product or process.
[003] Therefore, condensate drains are used in compressed air systems to remove the condensate from the compressed air. The condensate drains can be largely divided into timer-based condensate drain valve (electromagnetic solenoid drains) and integrated ball float and valve drains. In the integrated ball float and valve drains, as the ball float directly controls the drain hole, it is difficult to employ a drain nozzle size exceeding 3 mm, and as a result, scale deposits and other impurities inside the drain passage can easily clog and block the drain hole. Sometimes the float gets stuck up due to accumulation of dirt or scale deposit. The clogging of drain hole results in condensate getting carried away into compressed air system and the stuck up of the float results in compressed air loss. Thus, periodic disassembly and cleaning is required.
[004] In the electromagnetic timer-based solenoid drain, while condensate is collected at regular intervals and forcefully drained at preset times externally, compressed air is discharged to the outside together with the condensate. Thus, not only is energy lost, but an external power source must be connected to the drain during on-site installation of equipment, presenting limitations for the use of electromagnetic solenoid drains.
[005] Therefore, there exists a need for a system for removing liquid condensate from compressed air, which obviates the aforementioned drawbacks.
OBJECTS

[006] The principal object of embodiments herein is to provide a system and a method for removing liquid condensate from compressed air.
[007] Another object of embodiments herein is to achieve a reliable condensate removal in a variety of industrial and commercial environments.
[008] Another object of embodiments herein is to reduce energy consumption of an air compressor.
[009] Another object of embodiments herein is to eliminate loss of compressed air during draining of liquid condensate.
[0010] Another object of embodiments herein is to enhance the life of pneumatic valves, cylinders, seals, and other air components in the compressed air line thereby reducing service and replacement of parts.
[0011] Another object of embodiments herein is to eliminate corrosion in compressed air flow line thereby resulting in low-pressure drop in pipelines.
[0012] Another object of embodiments herein is to improve dew point.
[0013] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF DRAWINGS
[0014] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0015] Fig. 1 depicts a schematic diagram of a system for removing liquid condensate from compressed air, according to embodiments as disclosed herein;
[0016] Fig. 2 illustrates draining of the liquid condensate, according to embodiments as disclosed herein;
[0017] Fig. 3 illustrates a controller unit in communication with a liquid sensor and a control valve assembled to a storage tank, according to embodiments as disclosed herein; and
[0018] Fig. 4 depicts a flowchart indicating steps of a method for removing liquid condensate from compressed air, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0019] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0020] The embodiments herein achieve a system and a method for removing liquid condensate from compressed air. Referring now to the Figs 1 through 4, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0021] Fig. 1 depicts a schematic diagram of a system (100) for removing liquid condensate (L) from compressed air (A), according to embodiments as disclosed herein. Fig. 3 illustrates a controller unit (108) in communication with a liquid sensor (104) and a control valve (106) assembled to a storage tank (102), according to embodiments as disclosed herein. The system (100) includes storage tank (102), a liquid sensor (104), a control valve (106), a controller unit (108) and a level indicator (110). For the purpose of this description and ease of understanding, the system (100) is explained herein with below reference to removing liquid condensate (L) from compressed air (A) for use in an industrial plant. However, it is also within the scope of the invention to use/ practice the components of the system for removing liquid condensate from compressed air at any of an intercooler or drip leg or aftercooler or air dryer or air receiver or any other air compressed air components or filters or centrifugal separators or refrigerated dryers or at point of use, without otherwise deterring the intended function of the system (100) as can be deduced from the description and corresponding drawings. The air compressor (10) is adapted to compress the air and the compressed air flows through to an air dryer (20) through an after-cooler (15) (as shown in fig. 1).
[0022] The storage tank (102) is adapted to receive and accumulate compressed air (A) with liquid condensate (L) therein. The storage tank (102) includes an inlet channel (102A), an outlet channel (102B) and a drain channel (102C) (as shown in fig. 3). The inlet channel (102A) is defined near the top end of the storage tank (102). The inlet channel (102A) is coupled to the drain point of air dryer (20). The outlet channel (102B) is adapted to allow dry compressed air (A) to flow from the storage tank (102) to an air receiver (30) through a downstream side pipeline (40) (as shown in fig. 1 and fig. 2). The drain channel (102C) is defined at the bottom end of the storage tank (102). The inlet channel (102A) is adapted to allow the compressed air (A) along with liquid condensate (L) to flow from the air dryer (20) to the storage tank (102) due to a first pressure (P1) at the air dryer (20) is higher than a second pressure (P2) at the downstream side pipeline (40).
[0023] The liquid sensor (104) is coupled to the storage tank (102). The liquid sensor (104) is mounted on the storage tank (102) near its top end. At least a portion of the liquid sensor (104) is disposed inside the storage tank (102). The control valve (106) is coupled to the storage tank (102). The control valve (106) is at least an electric solenoid valve adapted to be coupled to the drain channel (102C) of the storage tank (102). The controller unit (108) in communication with the liquid sensor (104) and the control valve (106).
[0024] The liquid sensor (104) is adapted to send a drain signal to controller unit (108) when the liquid condensate (L) reaches a threshold level in the storage tank (102) and establishes contact with the liquid sensor (104) (as shown in fig. 2). The liquid sensor (104) operates on the impedance spectroscopy method. Further, the controller unit (108) is configured to actuate the control valve (106) which in turn discharges the liquid condensate (L) when the controller unit (108) receives the drain signal from the liquid sensor (104).
[0025] The level indicator (110) is adapted to indicate the level of liquid condensate (L) accumulated in the storage tank (102). The pressure gauge (112) is disposed on the storage tank (102).
[0026] Fig. 4 depicts a flowchart indicating steps of a method (200) for removing liquid condensate (L) from compressed air (A), according to embodiments as disclosed herein. At step (202), the method (200) includes receiving and accumulating, by a storage tank (102), compressed air (A) along with liquid condensate (L) therein. At step (204), the method (200) includes sending, by a liquid sensor (104), a drain signal to a controller unit (108) when the liquid condensate (L) reaches a threshold level in the storage tank (102) and establishes contact with the liquid sensor (104). At step (206), the method (200) includes discharging, by a control valve (106), the liquid condensate (L) when the controller valve (106) is operated by the controller unit (108) based on the drain signal sent by the liquid sensor (104) to the controller unit (108).
[0027] Further, the method (200) includes allowing dry compressed air (A) to flow from the storage tank (102) to an air receiver (30) through a downstream side pipeline (40). Further, the method (200) includes allowing compressed air (A) with liquid condensate (L) to flow from an air dryer (20) to the storage tank (102) due to a first pressure (P1) at the air dryer (20) is higher than a second pressure (P2) at the downstream side pipeline (40).
[0028] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein. , Claims:STATEMENT OF CLAIMS
We claim,
1. A system (100) for removing liquid condensate (L) from compressed air (A), said system (100) comprising:
a storage tank (102) adapted to receive and accumulate compressed air (A) with liquid condensate (L) therein;
a liquid sensor (104) coupled to said storage tank (102);
a control valve (106) coupled to said storage tank (102); and
a controller unit (108) in communication with said liquid sensor (104) and said control valve (106).

2. The system (100) as claimed in claim 1, wherein said liquid sensor (104) is adapted to send a drain signal to said controller unit (108) when said liquid condensate (L) reaches a threshold level in said storage tank (102) and establishes contact with said liquid sensor (104); and
said controller unit (108) is configured to actuate said control valve (106) which in turn discharges said liquid condensate (L) when said controller unit (108) receives said drain signal from said liquid sensor (104).

3. The system (100) as claimed in claim 1, wherein said storage tank (102) includes,
an inlet channel (102A) defined near a top end of said storage tank (102), wherein said inlet channel (102A) is coupled to an air dryer (20);
an outlet channel (102B) adapted to allow dry compressed air (A) to flow from said storage tank (102) to an air receiver (30) through a downstream side pipeline (40); and
a drain channel (102C) defined at a bottom end of said storage tank (102),
wherein
said inlet channel (102A) is adapted to allow said compressed air (A) along with liquid condensate (L) to flow from said air dryer (20) to said storage tank (102) due to a first pressure (P1) at said air dryer (20) is higher than a second pressure (P2) at said downstream side pipeline (40).

4. The system (100) as claimed in claim 3, wherein said control valve (106) is at least an electric solenoid valve adapted to be coupled to said drain channel (102C) of said storage tank (102); and
said liquid sensor (104) operates on the impedance spectroscopy method.

5. The system (100) as claimed in claim 1, wherein said liquid sensor (104) is mounted on said storage tank (102) near its top end, wherein at least a portion of said liquid sensor (104) is disposed inside said storage tank (102).

6. The system (100) as claimed in claim 1, wherein said system (100) includes a level indicator (110) adapted to indicate the level of liquid condensate (L) accumulated in said storage tank (102).

7. A method (200) for removing liquid condensate (L) from compressed air (A), said method (200) comprising:
receiving and accumulating, by a storage tank (102), compressed air (A) along with liquid condensate (L) therein;
sending, by a liquid sensor (104), a drain signal to a controller unit (108) when the liquid condensate (L) reaches a threshold level in the storage tank (102) and establishes contact with the liquid sensor (104); and
discharging, by a control valve (106), the liquid condensate (L) when the controller valve (106) is operated by the controller unit (108) based on the drain signal sent by the liquid sensor (104) to the controller unit (108).

8. The method (200) as claimed in claim 7, wherein said method (200) includes,
allowing dry compressed air (A) to flow from said storage tank (102) to an air receiver (30) through a downstream side pipeline (40); and
allowing compressed air (A) with liquid condensate (L) to flow from an air dryer (20) to the storage tank (102) due to a first pressure (P1) at the air dryer (20) is higher than a second pressure (P2) at the downstream side pipeline (40).