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.

What is claimed is: 
     
         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.